BOSCH P-Pump Disassembly

Summary

This comprehensive guide details the disassembly and inspection process for a P pump, emphasizing precision and careful handling. The script walks through the steps of preparing the workspace, draining lubricating oil, removing key components like the feed pump, top cover, and camshaft, and addressing the barrel assemblies. It highlights critical techniques for disassembling pumping elements, inspecting parts for wear, and replacing damaged components like rollers, plungers, and delivery valves. With a focus on maintaining proper order of parts and attention to detail, the video ensures that users can effectively perform maintenance on precision fuel injection equipment.

Takeaways

• 😀 Start by ensuring a clean work area to prevent contamination of precision fuel injection equipment.
• 😀 Always refer to written instructions, specifications, and torque values for accuracy during disassembly.
• 😀 Drain the lubricating oil from the P pump before starting the disassembly process.
• 😀 Install and tighten the drive coupling, but avoid over-torquing it during installation.
• 😀 Loosen the barrel assembly nuts, but do not remove them until later in the process.
• 😀 Use a tool to rotate the camshaft to TDC (Top Dead Center) before removing the camshaft components.
• 😀 Carefully lift each tappet and plunger, keeping track of each by cylinder number to avoid mix-ups.
• 😀 Use a puller tool to remove barrel assemblies; if unavailable, pry them loose gently.
• 😀 When removing the rack, ensure that the bushing retainer and pin are carefully handled for smooth disassembly.
• 😀 Inspect all parts after disassembly for any damage or wear such as cracks, scoring, or erosion.
• 😀 Always replace damaged parts like cracked delivery valves or worn camshafts to ensure high-quality repairs.

Q & A

What is the first step in disassembling the P pump?

The first step in disassembling the P pump is to drain out the lubricating oil.

Why is it important to have a clean work area during disassembly?

A clean work area is crucial because dirt and dust can damage the precision fuel injection equipment.

What is the purpose of the drive coupling in the disassembly process?

The drive coupling is installed to secure the pump while disassembling, but it should be tightened without torquing it.

What tools are needed for removing the cam shaft?

To remove the cam shaft, a tool is needed to rotate cam lobe number one to fully depress the TA to TDC, as well as a tool to lift and hold each TAET away from its cam lobe.

What should be done after loosening the knuts for all barrel assemblies?

After loosening the knuts, you should swing the pump to the other side and remove the plugs from the TAET holder.

How do you remove the plunger from the barrel assembly?

The plunger can be removed by lifting it with the lower spring seat straight up, ensuring that it is not dropped. It's important to keep track of each plunger by cylinder number.

What steps are involved in removing the rack from the pump?

To remove the rack, unscrew the block, remove the seat and spring, use a tool to remove the bushing retainer, and then slide out the rack with its bushing.

How can you ensure that the parts of each cylinder stay together during disassembly?

Using a parts tray helps keep each cylinder’s parts together, such as the plunger, barrel, and shims, preventing confusion and ensuring they remain paired correctly.

What are some common faults to look for during inspection of the components?

Common faults include cracks in the flange bushings, damage to delivery valve bodies, scored cam shafts, worn roller bearings, and eroded housing surfaces.

What is the proper way to inspect a delivery valve?

The delivery valve should be checked for scratches, wear marks, and cracks. If there is any damage, such as a hairline crack, the valve assembly must be replaced.