Engine Pump Instruction manual

Engine pump timing begins with the timing of the fuel injection pump drive gear to the camshaft gear.

The first step is the location of TDC of the compression stroke for cylinder Number 1.

Then, depending on the engine configuration, an alpha character on the injection pump drive gear will possibly need to be aligned with the mark on the camshaft gear.

This table must be used to maintain proper fuel injection pump-to-engine timing. The Control Parts

List (CPL) number from the engine dataplate and the Control Parts List Manual, Bulletin 3379133 or 4021327, must be used to determine whether the engine is certified, and if so, what year and regulating agency (EPA or CARB).

Given this information, use the following table to determine which letter on the fuel injection pump drive gear is aligned with the camshaft gear.

NOTE: Timing mark alignment is not required for the Nippondenso EP-9 or Bosch® in-line drive gear.

NOTE: The timing mark is not required for Bosch® VE and DP210 used on Tier II Industrial engines. For these engines, vary timing by using the Timing Check procedure.

To verify that the fuel injection pump is timed correctly, first check the alignment marks on the pump flange and gear housing.

NOTE: 1 mm of rotation past the timing mark will advance or retard (depending on direction of rotation) the pump timing by 1 degree.

The Lucas CAV DPA, DPS, Delphi DP210, Stanadyne DB4, and the Bosch® VE fuel injection pumps all have a provision for locking the pump shaft at a position corresponding to top dead center for cylinder Number 1. New and reconditioned fuel injection pumps must be received with the shafts located in this position.

At the point of injection, the keyway of the shaft will align with the delivery valve receiving the injection and the illustrated hash mark on the seal housing.

The Number 1 cylinder delivery valve is marked as illustrated.

Four cylinder = A

Six cylinder = D

Firing Order

Four Cylinder Six Cylinder

A =1

B = 3

D = 1

E = 5

C = 4

D = 2

F = 3

A = 6

B = 2

C = 4

The engine is equipped with an engine timing pin to locate top dead center (TDC) for cylinder

Number 1.

After precisely locating TDC for cylinder Number 1, the factory positions the timing pin assembly to the gear housing, using the timing pin and the hole in the camshaft gear. If the gear housing or timing pin assembly are removed, the same precision is required to relocate it.

If the timing pin assembly is incorrectly located, reposition the timing pin.

The flange of a replacement pump must be marked to align with the mark on the gear housing after installation.

During production, after the locked pump is fitted to the engine with cylinder Number 1 at top dead center (TDC), a mark is stamped on the gear housing and the pump flange. Thereafter, when these marks are aligned, the pump is correctly timed to the engine.

NOTE: The marks on the gear housing and the pump flange are unique to each engine.

See Service Tool Instruction, Bulletin 3400196 and Service Tool Catalog, Bulletin 3377710 to determine the appropriate Bosch® timing tool and adapter kit part numbers.

A special indicator can be used to measure the position of the Bosch® VE fuel injection pump plunger to check pump timing.