Section 5 • Fuel Systems

B Series Page 5-1

... I Systems

Page
Air Fuel Control Tube Replacement· Bosch P7100 .............................................................................. 5-71
Air Fuel Control Tube • Bosch VE ................................................................................... 5-70
Air In The Fuel System.................................................................................................................................... 5-17
Back Leakage Valve and CAV ·Replacement.. ................................................. 5-75
Cold Start Timing Advance • Electrical Solenoid Style........................................................... 5-36
KSB Electrical Solenoid - Inspection.............................................................................................................. 5-42
KSB Wiring Harness - Inspection................................................................................................................... 5-43
Troubleshsooting the Electrical Solenoid Style KSB .. .. ..... .................. ................ ............... ............. .......... ... ... 5-41
VE Pump Timing Advance Principles (With Electrical Solenoid KSB Installed)............................................... 5-38
VE Pump Timing Advance Principles (Without KSB) ............................... .... .......................... ........ ... ....... ....... 5-37
Cold Start Timing Advance System • Wax Motor Style .. .. .. .. .. .. .. .. ... .. .. .... .. .. .. .. .. .. .. .. .. . ... . ... . ... ... .. .. .. .. ... . 5-28
KSB Hardware Definition ............................................................................................................................... 5-31
KSB Wax Motor Element . .. .. ... . .. ... .. .. .. . .. . .. .. .. .. .. ... ... .. .. .. .. .. .. .. . .. ... .. ... . .. .. .. . ...... .. .. ... .. .. .... .. .. . .. .. . .. . .. .. .... .. .. .. . .. ... 5-34
Need For KSB on 1988 VE Pumps ................. ......... ........................ ... .................... .......... ................... .... ...... 5-28
Pump Mounted KSBs. .......... ...... ..... ..... ..... .......... ...... .......... ... .. ... .. ........ .. . .. .. ..................................... ..... ... .. ... 5-31
Remote Mounted KSB .. . .. .. ... .. . .. .. .. .. .. .. .... .. .. .. .... .. ... .. .. . .. .. . .. .... .. .. . .. .. .. ... . .. . .. .. ... ... ... .. .. ... .. . .. ... .. ... .. . .. .. .. .. . .. .. .. .. 5-32
Troubleshooting The Wax Motor KSB .. ..... .. .. ... .. . .. . .. .. .. .. .. .. ... .. .. . .. .. .. .. . .. . .... .. .. ... .. .. .. .. .. .. .... .. ... .. . .. .. . .. .. . .. . 5-33
VE Pump Timing Advance
VE Pump Timing Advance
Wax Motor Installed) ........ .......... ........ ........ ....... .......... ........
............... ..... .......... ...... .................... .................. ...... .... ..
5-30
5-29 I
External Leaks ........................................................................ 5-77
Fuel Drain Manifold.......................................................................................................................................... 5-51
Fuel Drain Manifold • Bosch P7100. .... ................... ............ .............. ........ ........ ........... .............. 5-69
Preparatory Steps:......................................................................................................................................... 5-69
Fuel Drain Manifold Me1rnace1m • Distributor 5-67
Fuel Filter • HeDU!Iceme 5-54
5-20
5-23
5-26
5-24
5-21
5-21
5-22
5-23
5-22
5-21
Fuel 5-45
Air 5-46
Fuel 5-46
Fuel 5-47
Governor 5-46
5-77
5-77
5-80
5-77
. ................................................................................................ 5-99
P7100 ................................................................................................................................................. 5-99
................................................................................................................................................... 5-100
Removal ... ... ... ... .. ... .. .. . ... .. .. .. ... .. ... ... . .... . .... . ... .... . .... . .. .. . .. . .. ... . ... . .... . ... .. .. . . ... . .. . .. .. ... . . ... .. . ... .. .. . .... .. ... .. . ... . .. .. .. . . 5-99
Fuel Bosch P7100 .... . .... . .... ......... ....... ........... ..... ....... ...... 5-59
Fuel • Distributor 5-58
Fuel 5-85
CAV 5-90
In-line Fuel 5-93

Tnewcamp Manuals
 Section 5 - Fuel Systems
Page 5-2 B Series

Page
Pump Timing Check- Lucas CAV DPA, Stanadyne DB4, Nippendenso EP-9, and Bosch P-7100 ................... 5-91
Stanadyne DB4 Fuel Injection Pump Timing .................................................................................................. 5-88
Timing Check - (Bosch VE Pump) ................................. ...................................... ............. ........... ............. ..... 5-90
Fuel Shut Off Solenoid Adjustment/Replacement- Bosch P7100 .................................................................. 5-73
Adjustment .................................................................................................................................................... 5-73
Fuel Shut Off Valve Replacement· Bosch VE ................................................................................................. 5-71
Fuel Shut Off Valve Replacement Stanadyne DB4 ......................................................................................... 5-74
Installation ..................................................................................................................................................... 5-75
Removal........................................................................................................................................................ 5-74
Fuel System - Service Tools.............................................................................................................................. 5-9
Fuel System Components and Flow.................................................................................................................. 5-5
Fuel System Identification ................................................................................................................................. 5-6
Fuel System Specifications .............................................. ................................................................................. 5-8
Distributor Type Fuel Injection Pumps.............................................................................................................. 5-8
In-Line Type Fuel Injection Pumps................................................................................................................... 5-8
Fuel Transfer Pump· Testing ........................................................................................................................... 5-10
Fuel Transfer Pump (Piston Style)- Diagnosing Malfunctions ......................................................................... 5-12
Test 1: Output Pressure Test (Diaphragm Style) ............................................................................................. 5-10
Test 1: Output Pressure Test (Piston Style) .. .. .. .. .. .... ..... .... ...... .... .. ... .... .. .. ... .. .. .. ... .. ... ... ... ... .. ..... ... .. ..... .. .... .. .. . 5-13
Test 2: Flow Volume Test (Diaphragm Style) ................................................................................................... 5-11
Test 2: Flow Volume Test (Piston Style).......................................................................................................... 5-14
Fuel Transfer Pump (Diaphragm Style) Diagnosing Malfunctions ................................................................. 5-10
Fuel Transfer Pump Replacement - Diaphragm Style..................................................................................... 5-60
Fuel Transfer Pump Replacement/Rebuild - Piston Style............................................................................... 5-62
Assembly....................................................................................................................................................... 5-63
Cleaning........................................................................................................................................................ 5-63
Installation ..................................................................................................................................................... 5-64
Removal ......................................................................... ............................................................................... 5-62
Fuel Water Separator/Filter Unit ...................................................................................................................... 5-18
General Information - Fuel Systems ... .. ...... ... ..... ..... ..... .. ... ... ........ .. ... ...... .. ....... ... ........ ....... ......... .. .. ... ..... ... ..... 5-4
Fuel System Components and Flow - Distributor Type Fuel Injection Pump ....... ..... ......................................... 5-4
Fuel System and - In-Line Fuel Injection Pump................................................................... 5-4
Pressure ......................................................................... 5-66
Pressure .................................................................. 5-64
Pressure lines ................................................................................................................................ 5-48
Idle Speed • Bosch .......................................... 5-105
Idle Speed -Distributor ............................................................................. 5-106
Injector- Replacement ................................................................................................................................... 5-106
Injectors ... ...... ... ....... .... ..... ....... ..... ..... ..... ...... .. ........ .. ... ..... ... ....... ... ........ .. .... ... ... .. ..... .... ......... ......... ..... ..... ... .... 5-50
KSB Harness - ... ....... ..... .. ... ..... .......... ... .. ...... .. .. ...... ... .. .. .............. ............... ... ............. ........ 5-34
Low Pressure Fuel Line Replacement- Bosch P7100 Fuel 5-56
- Distributor Pumps............................................................................ 5-55
Pressure Relief Valve Replacement • Bosch P7100 .. .. .. ...... ... .. ... .. .. .. .. .. .. .... .. .. .. .. .... .. ... .. ... .. ... .. ... ... ... .. .. ... .. .. .. . 5-69
Shut Down Injection • Troubleshooting .......... .................. ............. ................ 5-47
Solenoid Resistance Check........................................................................................................................... 5-48
Solenoid Voltage Check................................................................................................................................. 5-48
Wiring Guidelines:......................................................................................................................................... 5-47
Stanadyne DB4 (Generator Application) ...... .. ...... .. ..... ... ... ................ .. .. ... .. ........ ... ............... ..... ......... .... ..... .... 5-27
Speed Droop Governor - Adjustment ... ... .. ........ .. .. ... ..... ... ..... ... ..... ... ..... .. ................ ....... .. ..... ............ ..... ..... ... 5-27
Venting the Fuel Systems................................................................................................................................ 5-52
High Pressure Fuel Lines - Venting................................................................................................................ 5-53
Section 5 • Fuel Systems
B Series Page 5-3
Page
Injection Pumps - Venting.............................................................................................................................. 5-53
Low Pressure Lines and Fuel Filter - Venting................................................................................................. 5-52

Tnewcamp Manuals
General Information - Fuel Systems Section 5 - Fuel Systems
Page 5-4 B Series

General Information .. Fuel Systems

Fuel System Components -Distributor Type Fuel Injection Pump
Most of the engines will be equipped with a cam actuated fuel transfer pump. Two types of fuel transfer pumps
are available for rotary type fuel injection pumps.: a) A diaphragm style fuel transfer pump and 2) a piston style
fuel transfer pump. The piston style fuel transfer pump is offered as an option, and may be disassembled, cleaned
and reassembled, using a fuel transfer pump rebuild kit. Fuel flow begins as the fuel transfer pump pulls fuel from
the supply tank though a mandatory prefilter. The fuel transfer pump supplies low pressure fuel (21-35 kPa [3-5
psi]) to the fuel filter head, through the filter and then to the distributor injection pump.
The distributor pump builds the high injection pressures required for combustion, and routes the fuel through
individual high-pressure fuel lines to each injector.
When the high-pressure fuel reaches the injector, the pressure lifts the needle valve against the spring tension to
let the fuel enter the combustion chamber.
Any leakage past the needle valve enters the fuel drain manifold. The fuel drain manifold routes controlled venting
from the distributor injection pump and leakage from the injectors back into the fuel tank.
Fuel System Components and Flow - In-line Fuel Injection Pump
A cam-actuated piston style fuel fuel transfer pump provides positive fuel pressure to the fuel injection pump. Fuel
flow begins as the fuel transfer pump pulls fuel from the supply tank. The system should have a pre-fifter or screen
to remove larger contaminants from the fuel before reaching the fuel transfer pump. The fuel transfer pump supplies
low pressure fuel through the fuel filter head and filter to the fuel injection pump at 172 kPa [25 psi].
The Bosch P7100 fuel injection pump is used on higher rated automotive 91 B Series engines and all 94 B Series
automotive engines. The Nippondenso EP-9 is used on the higher horsepower marine B Series engine.
The fuel injection pump builds the high injection pressures required for combustion and routes the fuel through
high pressure fuel lines to each injector.
All B Series engines use closed-nozzle, hole-type injectors. When the high-pressure fuel reaches the injector, the
pressure lifts the needle valve against the spring tension to allow fuel to enter the combustion chamber.
Any leakage past the valve enters fuel drain manifold.
On engines equipped with the P7100 fuel injection pump, the manifold routes leakage from the injectors to the inlet
side of the fuel filter. On engines equipped with the Nippondenso EP-9 fuel injection pump, the manifold routes
leakage from the injectors to the supply tank.
Section 5 - Fuel Systems Fuel System Components and Flow
B Series Page 5-5

Fuel System Components and Flow

The following illustration identifies the components of the fuel system.

Fuel System

1. Fuel from Supply Tank

2. Pre-FIIter or Screen
3. Lift Pump
4. Fuel/Water Separator
5. Fuel Filter
6. Low Pressure Supply line
7. Turbo Boost control Line
8. Robert Bosch P7100
Injection Pump
SA. Robert Bosch Rotary
Injection Pump
9. Fuel Drain Manifold
10. High Pressure Line
11. Robert Bosch, 17mm Closed-
Nozzle, Hole Type Injectors
12. Fuel Return to Supply Tank

Tnewcamp Manuals
Fuel System Identification Section 5 - Fuel Systems
Page 5-6 B Series

Fuel System Identification

Beginning in 1991, the 8 Series engine will use six different fuel injection pumps depending on the horsepower
rating and application.

The Lucas CAV DPA distributor type fuel injection pump.

• Marine
• Industrial

fp901gp

The Lucas CAV DPS distributor type fuel injection pump.

• European automotive ratings.

Bosch VE pump.

~ 1991 low horsepower automotive ratings

fp901gr
Section 5 - Fuel Systems Fuel System Identification
B Series Page 5-7

The Stanadyne 084 distributor type fuel injection pump.

• Gensets

The Bosch P7100 in-line fuel injection pump.

• 1991 high horsepower automotive ratings
• 1994 automotive, all 68 ratings

BOSCH P7100
With RQV-K. Governor fp901gs

The Nippondenso EP-9 in-line fuel injection pump with

the RSV governor.
• higher horsepower marine rating

lp901gt

Tnewcamp Manuals
Fuel System Specifications Section 5 • Fuel Systems
Page 5-8 8 Series

Fuel System Specifications

Distributor Type Fuel Injection Pumps

483.9 48T3.9 48TA3.9 685.9 68T5.9 68TA5.9

Maximum Inlet Restriction to the ...................................................... 100 [4] .................................................... ..

Fuel Transfer Pump Must Not Ex-
ceed - mm Hg [in Hg]

Maximum Allowable Return Line .................................................... 518 [20.4] ................................................... .

Restriction - mm Hg [in Hg]

Maximum Allowable Pressure Drop .......................................................35 [5]. ...................................................... .

Across Fuel Filter - kPa [psi]

Maximum Inlet Pressure to the In- ......................................................70 [10] ..................................................... .

jection Pump Must Not Exceed -
kPa [psi]

In-Line Type Fuel Injection Pumps

Maximum Inlet Restriction to the ...................................................... 100 [4] .................................................... ..

Fuel Transfer Pump Must Not
Exceed mm Hg [in Hg]

Fuel Lift Pump Maximum Output ..................................................... 172 [25] ................................................... ..

Pressure - kPa [psi] @ Rated RPM

Fuel Filter Restriction (Maximum ....................................................... 35 [5] ...................................................... .

Pressure Drop Across Filters) - kPa
[psi]

Fuel Pump Gallery Pressure - kPa ..................................................... 140 [20] ................................................... ..

[psi] Minimum @ Rated

Fuel Return Maximum 0 "'''+ri..,·t."" • .................................................... 518

mm
Section 5 - Fuel Systems Fuel System • Service Toots
B Series Page 5·9

Fuel System - Service Tools

The following special tools are recommended to perform procedures in Section 5. The use of these
tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins
Authorized Repair Location.

Tool No. Tool Description Tool Illustration

Bosch Timing Tool (VE)

3377259
~ ..,.
3377259

Injector Puller
Used to pull the injector.
3823276

Injector Bore Brush

Used to clean the injector bore.
3822509

3822509

Used to the fuel pump gear.

Tnewcamp Manuals
Fuel Transfer Pump (Diaphragm Style) Diagnosing Malfunctions (5-01) Section 5 - Fuel Systems
Page 5-10 B Series

Fuel Transfer Pump (Diaphragm Style)

Diagnosing Malfunctions (5-01)
A malfunctioning fuel transfer pump can cause low power
from the engine. The diaphragm style pump cannot be
cleaned and rebuilt.
The transfer pump is mechanically driven by a lobe on the
camshaft. Wear on the lever or a damaged lobe can
reduce the pumping action.
(A) - Do not operate the fuel system with a suction re-
striction of more than 100 mm [4 in Hg].
If the diaphragm ruptures, fuel will drain from the weep
hole (B) in the housing.

Normal pressure drop across the filter is 21 kPa [3 psi],

maximum.
The pressure drop will increase as the filter removes
contamination from the fuel. Therefore, a worn transfer
pump will have reduced capacity to force fuel through a
dirty filter. This can cause low engine power.
NOTE: Frequent filter replacement to get full power from the
engine can indicate a worn transfer pump.

Fuel Transfer Pump - Testing (5-02)

The output of the fuel transfer pump can be checked two
ways.
Test 1: Measure pressure an in-line
gauge.
2: Measure the flow

Test 1: Output Pressure Test

Style)
Start the engine and measure the output pressure of the
fuel transfer pump using an in-line pressure gauge.
Minimum Pressure
21 kPa [3 psi]
Section 5 • Fuel Systems Fuel Transfer Pump • Testing (5-02)
B Series Page 5-11

Test 2: Flow Volume Test (Diaphragm Style)

Caution: To prevent the engine from starting, discon-
nect the fuel shutdown wiring. Residual fuel in the in-
jection pump may cause the engine to start.
Caution: Do not crank the starter for more than 30 sec-
onds at a time. Doing so may result In starter damage.

Disconnect the fuel shutdown solenoid wire and measure

the engine cranking speed with a hand held tachometer
(Part No. 3377462).

Caution: Leave the shutdown solenoid disconnected for

the following check.
Disconnect the output pressure line from the fuel transfer
pump and run it into a container.
Measure fuel transfer flow volume, while crank-
the the starter 30 seconds.

Use the chart in the illustration to find the correct flow volume P/N 3904374 [OZ.]
specification for the diaphragm fuel transfer pump. ml DIAPHRAGM
• Draw a straight vertical line above the measured cranking 425 14.4
RPM. 400 13.5
• Draw a straight horizontal line from the measured flow 375 J 12.7
volume to the engine cranking RPM vertical line to find the @I 350 I 11.9
intersection point. E 1/ 11.0
o Any intersection point above the required flow line indicates
.= 325 10.2
g 300 V
an acceptable flow. ~@
!1': 275 f - -
/ ~
9.3
o Any intersection point below the required flow line indicates ~ 250
r---- Y- ---- -·~ 8.5
unacceptable flow and a defective pump or too much line 225 7.6
restriction. 200 ~~Maximum Res;rlctlon I 6.1!
Example 1 Engine cranking speed 230 RPM 1~ 5~
Good Pump Flow volume 260 M1 [8.8 oz] 200 225 250 275 300 400
Engine Cranking Speed [RPM] ts900nb
Example 2 Engine cranking speed 290 RPM
Bad Pump Flow volume 240 M1 [8.1 oz]

Tnewcamp Manuals
Fuel Transfer Pump • Testing (5·02) Section 5 - Fuel Systems
Page 5-12 B Series

Fuel Transfer Pump (Piston Style)- Diagnos-

ing Malfunctions
The B series engine uses three different piston style fuel
transfer pumps. All three deliver different flow volumes.

Piston style fuel transfer pump, Part No. 3918076, is of-

fered as an option on B series engines equipped with
distributor type fuel injection pumps.
NOTE: Part No. 3918076 and 3918000 are identical in ap-
pearance. The pumping spring free length can be measured
to identify the fuel transfer pump.
Fuel transfer pump 3918076 spring free length 53.5 mm
[2 7/64 in].

fs9spta

fs9sptb

Piston style fuel transfer pump, Part No. 3921550 comes

standard on the 91 B series engines equipped with the
Bosch P7100 in-line fuel injection pumps.
Piston style fuel transfer pump, Part No. 3925709, comes
standard on the 94 B series engines equipped with the
Bosch P7100 in-line fuel injection pumps.

fs901gu
Section 5 - Fuel Systems Fuel Transfer Pump - Testing (5·02)
B Series Page 5-13

The piston style fuel transfer pump is mechanically driven Check

by a plunger running against a special lobe on the cam- Valves
shaft. The fuel transfer pump contains a pumping piston A B C
and check valves to control the flow of fuel, and bleed
back during engine shutdown.

fs901gv

Normal pressure drop across the fuel filter is 35 kPa [5 ~

psi], maximum. ~
The pressure drop will increase as the fuel filter removes
contamination from the fuel. Therefore, a worn fuel trans-
fer pump will have reduced capacity to force fuel through
a dirty fuel filter. This can cause low engine power.
NOTE: Frequent fuel filter replacement to get full power from
the engine can indicate a worn transfer pump.

The output of the piston style fuel transfer pump can be ~

checked two ways. \.[)
Test 1: pressure using an in-line
pressure
Test 2: Measure the flow

1:
Operate the measure the pressure OFF
the fuel transfer pump an in-line pressure gauge.
Minimum Pressure @ Rated Speed
172 kPa [25

Tnewcamp Manuals
Fuel Transfer
5=1
Section 5 • Fuel Systems Fuel Transfer Pump - Testing (5-02)
B Series Page 5-15

Use the chart in the illustration to find the correct flow volume ml [ozJ
specification for P/N 3918000 fuel transfer pump, used on the 300 350 11.9
HP B series marine engine.
• Draw a straight vertical line above the measured cranking 325 11.0
RPM.
• Draw a straight horizontal line from the measured flow ~ 1100 I/ 10.2

volume to the engine cranking RPM vertical line to find the

.2
~ V
~@/
275 1-- 9.3
intersection point.
• Any intersection point above the required flow line indicates ~ ":"L

an acceptable flow.
• Any intersection point below the required flow line indicates
11. 250

225
Vff---- ®r-- I
8.5

7.6
*Maximum Restriction
unacceptable flow and a defective pump or too much line 200 8.8
restriction. 200 225 250 275 300 400
Example 1 Engine cranking speed 240 RPM Engine Cranking Speed [RPM]
fs900nd
Good Pump Flow volume 260 M1 [8.8 oz]
Example 2 Engine cranking speed 280 RPM
Bad Pump Flow volume 235 M1 [7.9 oz]

Use the chart in the illustration to find the correct flow volume
specification for P/N 3917334 fuel transfer pump, used with the ml {oz]
Bosch P7100 in-line injection pump. eu ~~
800 20.3
• Draw a straight vertical line above the measured cranking 575 19.5
RPM. 550 18.6
sa 11.s
• Draw a straight horizontal line from the measured flow 500 1U
volume to the engine cranking RPM vertical line to find the 475 18.1
intersection point. 450 15.3
425 14.4
• Any intersection point above the required flow line indicates 400 13.8
an acceptable flow. 375 12.7
350 11.9
• Any intersection point below the required flow line indicates 3U 11.0
unacceptable flow and a defective pump or too much line 300 10.2
restriction. 275
200 225 250 275 300 400
9.3

Example 1 Engine cranking speed 240 RPM Engine Cranking Speed (RPM] fs900ne
Good Pump Flow volume 390 M1 [13.2 oz]
Example 2 Engine cranking speed 290 RPM
Bad Pump Flow volume 360 M1 [12.2 oz)

If the flow volume measured falls below the line in the

respective chart above, check inlet restriction before dis-
assembling and cleaning the fuel transfer pump.
W
(5n

Inlet restriction must not exceed 100 mm Hg [4 in Hg].

fs900nl

If the fuel is aerated or the volume is low, isolate the fuel

transfer pump by connecting the fuel transfer pump inlet
@
~.
....,.
to a temporary supply and perform the same check as
above.

Tnewcamp Manuals
Fuel Transfer Section 5 • Fuel Systems
5-16 B Series

If the fuel transfer pump delivers the required volume of

fuel from a temporary supply, check for restrictions or
suction leaks in the fuel circuit to the fuel transfer pump:
1 . Supply line
2. Pre-filter
3. Supply line
4. Supply tank
5. Tank vent

Look for a plugged supply tank vent first.

fs900sc

Replace or clean the pre-filter.

In cold weather look for gelled fuel blocking the pre-filter.

for kinks that can restrict the fuel lines.

Remove and blow out the fuel lines.
Section 5 • Fuel Systems
B Series

Air In System
A replacement of fuel supply lines, fuel filters, fuel
tion pump, high pressure fuel lines and injectors let
air enter the fuel system. Follow the specified procedure
to bleed the air from the system.

Since the fuel transfer pump provides a positive pressure

through the fuel filter and fuel supply line to the fuel
@
~.
~
injection pump, loose connections or defective seals will
show as a fuel leak.

The most common place for air to enter the fuel system ~
is between the inlet of the fuel transfer pump and the
tube in the fuel Fuel tanks that have the fuel
®
outlet at the will have a suction tube that ex-
tends down in the or holes the weld
that the can air enter the fuel

Tnewcamp Manuals
Fuel Water Separator/Filter Unit (5-04) Section 5 - Fuel Systems
Page 5-18 B Series

The pressure relief valve arrangement on the Bosch P7100

fuel injection pump in the supply side of the fuel circuit
creates a self-bleeding system for air introduced during
replacement of the supply side components.
Small amounts of air can be bled from the pump by
operating the hand primer on the fuel transfer pump or by
cranking the engine.

The Bosch P7100 fuel injection pump has a jump-over

tube to route return fuel and entrapped air from the pres-
sure relief valve directly to the supply tank.

The Nippondenso EP-9 in-line fuel injection pumps will

Manual require additional venting prior to initial start-up, pump
Venting Controlled
Venting replacement, or if the engine has been allowed to run out
of fuel.

Water
Filtration and separation of water from fuel is
tant for trouble-free operation and long life of the
system. Some of the clearances between the fuel
tion pump parts are very close. For this reason, the parts
can easily be damaged by rust formation and contami-
nants.
Be sure to use the correct

fl901ge
Section 5 - Fuel Systems
B Series

The element has a valve which can be opened regularly

to drain the collected water.

A dual water separator/filter adapter provides additional

filtering capacity. The fuel flows through the adapter to a
larger combination fuel water separator filter, and back to
the fuel filter for final filtering.

ff901gd

Regular maintenance, including draining moisture from

the fuel water separator/filter and supply tanks, is essen-
tial to keep water out of fuel.

1!900va

1991 model and newer automotive B series

with the Bosch P7100 in-line
the fuel filter at the rear of the intake
as shown.

Tnewcamp Manuals
Fuel Injection Pump (Distributor Type) - Troubleshooting (5-05) Section 5 • Fuel Systems
Page 5-20 B Series

Fuel Injection Pump (Distributor Type)

-Troubleshooting (5-05)
The fuel injection pumps, Bosch VE, Lucas CAV DPA,
Stanadyne DB4, and Lucas CAV DPS, are rotary distrib-
utor pumps. These pumps perform the four basic func-
Bosch VE tions of:
1. Producing the high fuel pressure required for injection.
2. Metering the exact amount of fuel for each injection
cycle.
3. Distributing the high pressure, metered fuel to each
fp901gy
cylinder at the precise time.
4. Varying the timing relative to engine speed.

A single plunger or rotor is used by the fuel injection

pumps to develop and distribute the high pressure re-
quired for injection.
A four-cylinder Robert Bosch VE fuel injection pump
plunger is shown in this illustration.

A four-cylinder Lucas CAV DPA rotor is shown in this

illustration.
A worn or damaged rotor or plunger can affect the pres-
sure and amount of fuel injected, thus reducing the power
from the Generally, if the injection is
one outlet, it will deliver from

fp902ga 2

A rotor with two plungers is used by the Stanadyne

DB4 injection pump to develop and distribute the high
pressure required for fuel injection.
A DB4 rotor is shown in illustration.
A worn or damaged rotor or plunger can affect the pres-
sure and amount of fuel injected, thus reducing the power
from the engine. Generally, if the pump is injecting fuel
from one outlet, it will deliver from all outlets.
Section 5 - Fuel Systems Fuel Injection Pump (Distributor Type) - Troubleshooting (5-05)
B Series Page 5-21

Governor Malfunctions
Balance between the governor flyweights and control le-
ver position controls the metering of the amount of fuel to Governor
be injected. Flyweights
The fuel injection pump governor performance and set-
ting can affect engine power. Special equipment and qual-
ified personnel are required to verify governor perfor-
mance. If the seals are broken on the external Robert
Bosch VE adjustment screw, the fuel rate may be out of
adjustment.

Balance fp902gb

The Lucas CAV DPA/DPS fuel injection pump uses a

coded spring connection to change the governor setting.
Incorrect connection of the governor spring can affect
performance.
Adjustments and rating changes are described in this
section.

Fuel Control Lever Travel and Adjustment

The amount of fuel inJ·ected and subsequently the speed ~
and power from the engine is controlled by the fuel control ~
lever. Restricted travel of the lever can cause low power.
check for travel of the lever when
a low power

Stanadyne Fuel
ment Screw
The low idle adjustment screw on the
pump is mounted on the control lever <:~~c:::">rn
adjustment screw can be used to increase the idle speed
to compensate for accessory loading. The low idle ad-
justment scrf.lw must be adjusted by an authorized ser-
vice dealer and resealed.
NOTE: Never turn the idle adjusting screw out (reduce
speed) on the speed drop governor equipped fuel injection
pump; this can result in disengagement of the throttle lever
from the guide bushing.

Tnewcamp Manuals
Fuel Injection (5-05) Section 5 - Fuel Systems
Page 5-22 B Series

The high idle adjustment screw (A) is sealed. The ad-

justment screw on the DB4 fuel injection pump is mounted
on the control level assembly. The high idle adjustment
screw must be adjusted by an authorized service dealer.
The speed droop adjustment screw (B) is located above
the delivery head. The fuel pump governor sensitivity can
be adjusted to increase or decrease governor regulation.

lucas CAV DPA/DPS Fuel Injection Pump

Adjustment Screws
The idle adjustment screw provides a stop for the lever at
low speed. The adjustment screw can be used to increase
idle speed for accessory loading or, if required, to lower
the idle speed. The high idle screw is sealed and must be
adjusted by an authorized repair shop, and then resealed.
A - Idle screw
B - High idle screw

lp9asga

Robert Bosch VE Fuel Injection Pump

Adjustment Screws
A - Idle Screw
B- Idle
screw on both fuel
for The
screws are sealed. of
must be an authorized fuel
pump service resealed.
The speed screw can be to derate
engines.

fuel control lever on the

is indexed to shaft pump
calibration. If lever has been removed and reinstalled
inl"'nrr'~'~~~"'ti'IJ engine speed and power will be affected.
Section 5 - Fuel Systems Fuel Injection Pump (Distributor Type) - Troubleshooting (5-05)
B Series Page 5-23

Manual Shut Down levers

Both fuel injection pumps are equipped with mechanical
shut down levers. These levers are spring-loaded in the
run position. Not all applications will use these manual
shut down controls and there will be no cable or rod
connected to the lever.
NOTE: Partial actuation of the mechanical shut down levers
will affect fuel flow and engine power.

fp91vwb

Low power or the inability to stop the engine with the

manual shut down control can be corrected by adjusting
the cable/rod length to permit stop-to-stop lever travel.

I
\, __ L')CAS CAV DPA/DPS fp91vua

Low power or the inability to stop the engine with the

manual shut down control can be corrected by adjusting
the cable or rod length to permit stop-to-stop lever travel.

Advance
Regulated pressure produced by a vane supply pump in
both fuel injection pumps is used to advance the timing
as the engine speed increases. A return spring is used to
retard the timing as the engine speed is reduced. If a
spring should break, the timing will go to the advance
position resulting in torque loss, a fuel knock and possible
engine overheating.
Retarded (late) timing will result in torque loss, high fuel
consumption and white to black smoke.
fp902gc

Tnewcamp Manuals
 - Troubleshooting (5·05) Section 5 • Fuel Systems
B Series

The Lucas CAV DPA/DPS advance timing mechanism

uses a check ball in the circuit which, if omitted during
assembly, result in no timing advance. If the fuel
injection pump has been replaced or the mechanism has
been removed to fix a leak, the problem can be that the
check ball is missing.

fp9cbga

Electrical Shut Off Valves

The fuel injection pumps are equipped with electrical shut
off valves. These solenoid-operated valves block the sup-
ply of fuel to the high pressure pumping and distribution
components.
The Robert Bosch VE shut off valve is located at the top,
rear of pump.

The Lucas CAV DPA/DPS shut off valve is located at the

bottom rear of the pump.
Both 12 and 24 and
solenoids are available.

lv901ga

DB4 shut solenoid is locate!d under

governor cover.
Both 12 volt 24 volt and
solenoids are
Section 5 - Fuel Systems Fuel Injection Pump
B Series

Test the shutdown solenoid on the Stanadyne DB4 fuel

injection pump by applyng an electrical current to the
terminals and listening for an audible "click". If a solid
"click" is heard, the solenoid is operating freely.
Caution: Do not check energize-to-run solenoid opera-
tion with governor cover removed from the fuel injection
pump.
Use the following values to check energize-to-run sole-
noids with an ohmmeter:
Stanadyne DB4 Solenoid
Volts to Energize
Volts (Minimum)
12 8.8
24 17.6

When the valve on the Lucas CAV DPAIDPS pump opens, ~

a "click" can be heard. ~

Use the following values to check the solenoid with an

ohmmeter.

CAV Solenoid Values

Resistance Volts to Energize
Volts Ohms (Minimum)
12 9@ 22°C [71.6°F] 9
24 36@ 22°C [71.6°F] 18

The Robert Bosch valve does not make a very audible ~

sound when actuated, but it can be checked with an ~
ohmmeter for the following values:

Caution: Do not connect

lenoid when plunger has been r~~>rwu,.,>~,..fl"i
plunger, valve can be
Malfunctioning valves and electrical
can be diagnosed the
then reinstall the

Tnewcamp Manuals
Fuel Injection Pump (Distributor Type) - Troubleshooting (5-05) Section 5 - Fuel Systems
Page 5-26 B Series

Caution: Use the mechanical shut down lever to stop the

engine.
If the engine will start without the valve, the valve or the
wiring to the valve is malfunctioning.
This method of removing the plunger to start the engine
can be used if necessary to move the equipment to a
service location.

Delivery Valves (Back Leakage Valves On

Lucas CAV Pumps)
There is a valve for each discharge tube. The purpose of
the valve is to control the residual pressure in the high
pressure line. A malfunctioning valve will cause an im-
balance of the residual pressure resulting in rough engine
operation or surging.
Section
B Series

Tnewcamp Manuals
Cold Start Timing Advance System (KSB) - Wax Motor Style (5-07) Section 5 - Fuel Systems
Page 5-28 13 Series

Cold Start Timing Advance System (KSB) - Wax Motor Style (5-07)
The wax motor style KSB is used on pre-1991 B series automotive engine ratings using the Bosch VE fuel pump.
NOTE: The electrical solenoid style KSB is used on 1991 model and newer B series atuomotive engine ratings using
the Bosch VE fuel injection pump. See Procedure (5-08), Cold Start Timing Advance System (KSB) - Electrical Solenoid
Style, for additional information.

Wax Motor Style KSB Electrical Solenoid Style KSB

Note: Temperature switch is located in coolant jacket. Note: Temperature switch is located in intake manifold.

Need For KSB on 1988 Pumps

1988 emission requirements prompted the need for a cold start timing advance system (KSB) to minimize white
smoke.
After the engine starts, the wax motor style KSB fully advances the ignition timing at low idle until the engine warms
up. The KSB is not functional after the engine reaches 160°F coolant temperature.
Section 5 - Fuel Systems Cold Start Timing Advance System (KSB) - Wax Motor Style
B Series Page

VE Pump Timing Advance Principles (Without KSB)

Pump housing pressure acts on an internal timing piston (1 ), Figure 1, to partially advance the injection
idle, and fully advance the timing when the engine RPM reaches approximately 60% of rated speed. As
pressure increases, timing advances.
The pump housing pressure is controlled by the pressure regulator valve (2) (a spring loaded slider The
valve is shown in the open and closed position.
When housing pressure is low, the spring (3) forces the slider (4) into the closed position. This the
pressure to increase by preventing fuel draining through the return passage (5).
As housing pressure increases, it forces the slider (4) to compress the spring (3). This action opens the return
passage (5) and relieves the housing pressure.
A relief port (6), located on the spring side of the slider valve, allows fuel that seeps past the slider (4) to drain.
Relief port drainage is necessary to avoid a hydraulic lock of the slider valve, which would render the pressure
regulator valve (2) inoperable. In fact, it is this characteristic that is used in conjunction with the KSB to advance
the timing during cold engine operation.

*Advanced
Rotated 90 Degrees for

1, VE pump timing, regulated and closing the pressure valve.

Tnewcamp Manuals
Cold Start Timing Advance System (KSB) - Wax Motor Style
Page 5-30

VE Pump Timing Advance Principles (With Wax Motor KSB

The KSB introduces a new fuel line (1), Figure 2, which routes fuel from the relief port
valve (3) to a pressure holeing valve (4), bypassing the normal return passage (6),
The pressure holding valve (4), Figure 2, is closed when the engine is cold. When
regulating valve (3) attempts to regulate fuel pressure as before (without KSB) but the
now meets a 'dead end' at the closed pressure holding valve (4). This action hydraulically
regulator slider valve (4), Figure 1.
Housing pressure (5), Figure 2, is not regulated because the pressure regulator valve
pressure continues to increase. This action fully advances the timing. The
pressure holding valve (4) is opened.
The pressure holding valve (4), Figure 3, is opened by the expansion of an internal wax (6). When the wax
pellet expands, it causes the pin (7) to extend and open the pressure holding valve (4). wax pellet is expanded
by a resistance heating element. This element is wired to the shut down solenoid valve (8) and receives current
when a thermal switch (9) in the engine block is closed. This switch actuates at 160°F.
Fuel from the relief port of the pressure regulating valve now has a drain path (10) through the pressure holding
valve (4) (which is now open) to an alternate drain. The pressure regulator valve resumes normal operation and
the injection timing is regulated accordingly.

Normally Open Open

Coolant Temp Switch (160°) Coolant Temp Switch

To Thermal
From Key Switch
Switch ~~ Block

2, operation (pressure
"''"''"'"''"• no pressure regulation, advanced
Section 5 - Fuel Systems Cold Start Timing Advance System (KSB) - Wax Motor Style (5-07}
B Series Page 5-31

KSB Hardware Definition

There are currently two versions of pump mounted wax motor style KSBs released in the Cummins system and
one remote mounted version. The remote mounted option is necessary in applications where the pump mounted
KSB causes interference (i.e. with the air compressor, etc.).

Pump Mounted KSBs

The early pump mounted KSB is a different design using two control lines. The two line version was superseded
in mid-1988 with a one control line version which is the current design used for both production and service.
There is no remote mount hardware available for the two control line KSB so they cannot be remote mounted.

One Control Line KSB

Two Control Line KSB

i. KSB (one control

2. Harness
Part 3918364
Part Number 3918431
3. 1 Switch
Part Number 3915945

Tnewcamp Manuals
Cold Start Timing Advance System (KSB) - Wax Motor Style (5-07) Section 5 - Fuel Systems
Page 5-32 · B Series

Remote Mounted KSB

The remote mounted KSB is used on B series automotive
engines which have an air compressor.

Caution: Most pumps will have a shim between the KSB

and the timing piston. This shim must be reassembled
between the cover plate and the timing piston. If this
shim sticks to the KSB and is installed with the remote
mounting hardware, it will block the regulating valve
drain path and damage the pump. This damage is usually
evidenced by a fuel leak.

cs900wb
c
1/l
Rear The four cylinder engine using remote mounting requires
the temperature switch to be installed in the cylinder head
Location
as illustrated.

~·~
Section 5 - Fuel Systems Cold Start Timing Advance System (KSB) - Wax Motor Style (5-07)
B Series Page 5-33

Troubleshooting The Wax Motor Style KSB

27mm
Remove the temperature switch.

-r-
cs9swma

Caution: The switches are not interchangeable. White

smoke will be present if the wrong temperature switch is
used.
Notes: Part
Number
1) The wax motor KSB (used on pre-91 engines) uses a
160°F [71 °C] normally open coolant temperature
switch, Part No. 3915945.
2) The electrical solenoid style KSB (used on 91 models
and newer) uses a 90°F [32°C] normally closed intake
manifold temperature switch, Part No. 3921642.
cs900gv

The operation of the temperature switch for the wax motor

style KSB can be checked by connecting a volt ohmmeter Plastic Tang Part Number
to the switch, placing the switch in water, and then heating 3915945
the water to 160°F [71 °C].
on the left when viewed

Used

cs9swvb

Check the water with a thermometer.

indicate an open circuit below 160°F
a closed circuit above 160°F °C].
"'f.J""'"'" the if necessary.

Tnewcamp Manuals
KSB Wiring Harness· Inspection (5-08) Section 5 - Fuel Systems
Page 5-34 B Series

KSB Wax Motor Element

22 mm
Loosen and remove the KSB electrical element from the
KSB housing.

cs9swmb

Apply 12 volts to the electrical terminal and a ground strap

to the hexagonal portion of the element. Observe for
extensional movement of the plunger. If the plunger does
not move after approximately one minute, check to make
sure the element has been correctly connected to ground.
If all connections are correct and the plunger does not
move, the element is defective and must be replaced.
NOTE: The amount of plunger movement will vary depend-
ing upon the ambient temperature.

22 mm
Install the original element or a replacement into the KSB
housing.
Torque Value: 22 N•m [16

cs9swmb

Fuel Pump Shutdown KSB Wi Harness .. Inspection

Solenoid Connector
(5-08)
The wiring harness used on the wax motor style KSB can
be inspected using a volt/ohm meter.
NOTE: Pin 'C' of the metro-pack connector is blank on the
wax motor style KSB wiring harness.

KSB Wax Motor

Connector
Section 5 - Fuel Systems KSB Wiring Harness - Inspection (5-08)
B Series Page 5-35

Use a volt/ohm meter to perform a continuity check be- ~

tween port 'N of the metro-pack connector and the female \..[)
spade connector at the fuel pump shut down solenoid
connector.
Repair the wire if there is an open circuit.
Ohms Resistance - Less than 10.

Fuel Pump Shutdown

Solenoid Connector cs900na

Use a volt/ohm meter to perform a continuity check be-

tween Port 'B' of the metro-pack connector and the fe-
male spade connector at the KSB wax motor connector.
Repair the wire if there is an open circuit.
Ohms Resistance - Less than 10.

Tnewcamp Manuals
Cold Start Timing Advance System (KSB) • Electrical Solenoid Style (5-09) Section 5 - Fuel Systems
Page 5-36 B Series

Cold Start Timing Advance System (KSB)- Electrical Solenoid Style (5-09)
The electrical solenoid style KSB is used on 1991 model and newer B series automotive engine ratings using the
Bosch VE fuel pump.
Note: The wax motor style KSB is used on pre-1991 B series automotive engine ratings using the Bosch
VE fuel pump. See Section (5-07), Cold Start Timing Advance System (KSB)- Wax Motor Style, for additional
information.

Wax Motor Style KSB Electrical Solenoid Style KSB

Note: Temperature switch is located in coolant jacket. Note: Temperature switch is located in intake manifold.
Section 5 - Fuel Systems Cold Start Timing Advance System (KSB)- Electrical Solenoid Style (5-09)
B Series Page 5-37

VE Pump Timing Advance Principles (Without KSB)

Pump housing pressure acts on an internal timing piston (1), Figure 1, to partially advance the injection timing at
idle, and fully advance the timing when the engine RPM reaches approximately 60% of rated speed. As pump
pressure increases, timing advances.
The pump housing pressure is controlled by the pressure regulator valve (2) (a spring loaded slider valve). The
valve is shown in the open and closed position.
When housing pressure is low, the spring (3) forces the slider (4) into the closed position. This permits the housing
pressure to increase by preventing fuel drainage through the return passage (5).
As housing pressure increases, it forces the slider (4) to compress the spring (3). This action opens the return
passage (5) and relieves the housing pressure.
A relief port (6) located on the spring side of the slider valve, allows fuel that seeps past the slider (4) to drain. Relief
port drainage is necessary to avoid a hydraulic lock of the slider valve, which would render the pressure regulator
valve (2) inoperable. In fact, it is this characteristic that is used in conjunction with the KSB to advance the timing
during cold engine operation.

VE Pump
without KSB

"' Advanced Piston Assembly

Rotated 90 Degrees for Clarity
lp900gf

Figure 1, VE pump timing, regulated by opening and closing the pressure regulator valve.

Tnewcamp Manuals
Cold Start Timing Advance System (KSB) • Electrical Solenoid Style (5-09) Section 5 - Fuel Systems
Page 5-38 B Series

Pump Timing Advance Principles (With Electrical Solenoid KSB Installed)

The KSB introduces a new fuel line (1), Figure 2, which routes fuel from the relief port (2) of the pressure regulator
valve (3) to the plunger end (6), Figure 3, of the electrical solenoid, bypassing the normal return passage (6), Figure
1.
With·the key switch on, current flows from the key switch line to the 90°F normally closed intake manifold switch
to the 12V electrical KSB solenoid (see Figure 2). When the engine starts, the pressure regulating valve (3) attempts
to regulate fuel pressure as before (without KSB) but the fuel from the relief port (2) now meets a 'dead end' at
the plunger of the KSB solenoid (6), Figure 3. With the key switch on, the plunger moves outward and closes off
the flow path of the fuel (8), Figure 3. This action hydraulically locks (closes) the pressure regulator slider valve
(4), Figure 1.
Housing pressure (5), Figure 2, is not regulated because the pressure regulator valve (3) is inoperable and so the
pressure continues to increase. This action fully advances the timing. The timing remains fully advanced until the
plunger (6), Figure 3, is opened and fuel is allowed to drain through fuel drain flow path (8), Figure 3.
When the intake manifold temperature reaches 90°F, the 90°F normally closed IMT switch opens and voltage is
no longer applied to the KSB solenoid (10). With no voltage applied to the KSB solenoid (13), fuel pressure
overcomes the plunger force and pushes the plunger back to open the fuel drain flow path (8).
Fuel from the relief port of the pressure regulating valve now has a drain path (8), Figure 4, past the KSB solenoid
plunger (6), Figure 4 {which is now open) to the drain. The pressure regulator valve resumes normal operation and
the injection timing is regulated accordingly.
The electrical solenoid style KSB is also equipped with a pressure relief valve (7), Figure 3. If the engine is taken
to high idle with the KSB solenoid plunger in the closed position (6), Figure 3, housing pressure can increase
enough to rupture the fuel pump housing. The pressure relief valve (7), Figure 3, will pop off its seat before this
occurs, however. At a pressure of 4 bar (60 psi), the pressure relief valve (7), Figure 3, opens and allows fuel to
drain through an alternate flow path (9), Figure 3.
Section 5 • Fuel Systems Cold Start Timing Advance System (KSB) • Electrical Solenoid Style (5-09)
B Series Page 5-39

VE Pump Timing Advance Principles (With Electrical Solenoid KSB Installed)

From Key
Switch

To Thermal
Switch in
Intake Manifold

lp900gh

Figure 2: Bosch VE Fuel Pump With Electrical Solenoid KSB

From From
1 IMT Switch IMT Switch

8 lp900gl

Figure 3: Cold Engine Operation (Less Figure 4: Warm Engine Operation (More
Than 90°F IMT), Advanced Timing Than 90°F IMT), Retarded Timing

Tnewcamp Manuals
Cold Start Timing Advance System (KSB) • Electrical Solenoid Style (5-09) Section 5 - Fuel Systems
Page 5-40 B Series

Two types of electrical solenoid style KSB valves are avail-

able.
The first type is the pump mounted KSB, as shown.

The second type is the remote mounted KSB, as shown.

The remote mounted KSB is used on B series automotive
engines which have an air compressor.

Caution: Most pumps will have a shim between the KSB

and the timing piston. This shim must be reassembled
between the cover plate and the timing If this
shim sticks to the KSB and is installed the remote
mounting hardware, it will the valve
drain path and the pump. This nl'llm.Rinll'l>
evidenced a

Both the 4 and 6 cylinder have the switch

mounted in the intake manifold as shown.
Section 5 - Fuel Systems Cold Start Timing Advance System (KSB) - Electrical Solenoid Style (5-09)
B Series Page 5-41

Troubleshsooting the Electrical Solenoid

Style KSB
27mm
Remove the temperature switch from the intake manifold.

Caution: The switches are not interchangeable. White

smoke will be present if the wrong temperature switch is
used.
Check the part number to be sure the correct temperature Part
switch is used. Number
NOTE: The electrical solenoid style KSB (used on 91 models
and newer) uses a 90°F [32°C] normally closed intake man-
ifold temperature switch, Part No. 3921642.

cs900gv

Although the electrical solenoid style KSB uses an intake

manifold temperature switch, the operation of the switch Part Number
can be checked by connecting a volt/ohm meter to the 3920598
switch, placing the switch in ice water, and then heating
the water to 90°F [32°C].
Connect the VOM to the two outside
atu re switch.

Not Used
cs9swwa

Check the water temperature with a thermometer.

The VOM should indicate a closed circuit below 90°F
[32°C] and an open circuit above 90°F [32°C].
Replace the switch if necessary.

Tnewcamp Manuals
Cold Start Advance System (KSB) - Electrical Solenoid Style (5·09) Section 5 • Fuel Systems
Page 5-42 B Series

KSB Electrical Solenoid - Inspection

24mm
Remove the KSB electrical solenoid from the KSB housing.

cs900ma

Apply 12 volts to the electrical terminal and ground the

hexagonal portion of the element. The magnetic coil of the
solenoid must push the plunger outward.
If the plunger does not push outward when voltage is
applied, the solenoid is defective and must be replaced.
12 Volts

cs9swve

24 mm
Install the original solenoid or a replacement into the KSB
housing.
Value: 22 NCDm [16

cs900ma

17 mm
Remove the relief valve.

cs9vama
Section 5 . Fuel !'o>u•=T,..!m!l: Cold Start Timing Advance System (KSB) - Electrical Solenoid Style (5-09)
B S!Ol~'il'l~ Page 5-43

flush the pressure relief valve with cleaning

solution.

cs9vaea

Use a very small to be sure the check ball is

not sticking.
NOTE: A or malfunctioning pressure relief valve will
result in smoke or a fuel pump housing.
the pressure relief valve assembly if necessary.

cs9cbsa

17 mm
relief valve or a

cs9vama

with CPL 579 do have a resistor in the

harness.

Tnewcamp Manuals
Cold Start Timing Advance System (KSB) - Electrical Solenoid Style (5-09) Section 5 - Fuel Systems
Page 5-44 B Series

Engines with CPL 1351 must be wired with the resistor

in the harness.

The wiring harness used on the electric solenoid style

KSB can be inspected using a volt/ohm meter.
NOTE: Pin 'B' of the metro-pack connector is blank on the
electric solenoid style KSB wiring harness.

The electric solenoid style KSB wiring harness contains

30hm a 3 ohm resistor in the wire leading from Port 'C' of the
Resistor --:::w: metro-pack connector to the KSB electrical solenoid con-
nector.
The 3 ohm is mounted to a
as a 'heat sink' to absorb that is
resistor.

KSB Electrical
Solenoid Connector
cs900oa

Use a volt/ohm meter to perform a check be-

tween Port 'C' of the metro-pack connector and the KSB
solenoid connector.
the wire if there is an open
(Spec = Less than 10 ohms).
Section 5 - Fuel Systems Fuel Injection Pump (In-Line Type)- Troubleshooting (5-10)
B Series Page 5-45

Use a volt/ohm meter to perform a continuity check be-

tween Port W of the metro-pack connector and the fuel
pump shut down solenoid connector.
Repair the wire if there is an open circuit.
(Spec = Less than 10 ohms).

Fuel Injection Pump (In-Line Type) -

Troubleshooting (5-10)
Beginning in 1991, the B series engine used the Bosch
P7100 in-line fuel injection pump on higher horsepower
automotive ratings. In 1994 all automotive 68 series en-
gines will use the Bosch P-7100 in-line fuel injection pump.

BOSCH
P7100
fp902gd

The 8 series engine also uses the Nippondenso EP-9

with RSV governor on 250 and 300 horsepower marine
rating.
Refer to the B Series Marine
Bulletin No.

lp902ge

The fuel pump the three basic func-

tions of:
1) Producing fuel pressure for injec-
tion.
2) Metering the exact amount of fuel for each
cycle.
3) Delivering the high pressure fuel to each
cylinder at precise time.

~====================~
ls901gx

Tnewcamp Manuals
 individual
distribute
in the pump affect

Balance
and control le-
ver amount of fuel to
be

fp91vna
Section 5 - Fuel Systems Shut Down Solenoid (In-Line Type Injection Pump)- Troubleshooting (5-11)
B Series Page 5-47

Fuel Injection Pump Idle Adjustment Screws

The idle adjustment screw provides a stop for the lever at
low speed. The adjustment screw can be used to increase
idle speed for accessory loading or, if required, to lower
the idle speed.
The high speed screw is set at the factory and can only
be adjusted at a certified fuel pump shop.
A - Idle Screw
B - High Idle Screw

Shut Down Solenoid (In-Line Type

Injection Pump) - Troubleshooting
(5-11)
Engines using the Bosch P7100 fuel injection pump with
the RQVK governor are equipped with the synchro-start
fuel shut off solenoid to actuate the shut off lever. Both 12
volt and 24 volt external fuel shut off solenoids are avail-
able.
NOTE: Refer to Procedure (5-31), Fuel Shut Off Solenoid
Adjustment/Replacement - Bosch P7100, for instructions to
replace and adjust the synchro-start solenoid. fv900ka

The synchro-start has a weatherpack connector with 3

wires in it.
Col or Description Weatherpack Port
'8'ra'CK Ground
White Pull In 'B'
Red Hold In 'A:

Guidelines: EXISTING
STARTING
SYSTEM
Refer to the chart below to find the correct gauge size and ~--------~
length of continuous wire for the white (pull-in) wire, which
connects to the solenoid wiring. I i
STARTER
CONTACTOR
(RELAY)

0-4.5 ft 0-7.0 ft 0-11 ft

KEY SWITCH POSITIONS
Gauge 14 12 10 OFF NO POWER TO ENGINE
ON POWER TO ACCESSORIES
NOTE: 14 gauge wire is required for the red (hold-in) wire, AND TO HOLD COIL OF
FUEL SOLENOID ('A' LEAD)

which connects to the "Run" terminal on the ignition switch. START POWER TO 'PULL IN' COIL
OF FUEL SOLENOID ('B' LEAD)
FUEL SOLENOID
'---<>------irfljrl WIRING DIAGRAM
NOTE: The black (ground) wire must be the same size as the 12 voc
BATTERY
FOR GROUNDED SYSTEM
fs901
white (pull-in) wire.

Tnewcamp Manuals
Pressure Fuel Lines Section 5 - Fuel Systems
5-48 B Series

Solenoid Resistance Check

The synchro-start solenoid can be checked using a volt-
ohmmeter. Disconnect the wiring harness and check the
solenoid resistance.

Resistance
Solenoid Min Ohms
Voltage Pull-in Hold-in
12 0.22 11.1
24 0.82 41.3

Solenoid Voltage Check

If the synchro-start solenoid checks good, the problem is with
the wiring circuit to the solenoid.
To preform the solenoid voltage check, connect the wiring
harness and apply voltage to the solenoid with the ignition key
as follows:
1. With the key in the run position check the voltage hold-in.
2. With the shut down lever held in the shut down position
move the key to the start position and check the pull-in
voltage.
Battery Min Voltage
Voltage Pull-in Hold-in
12 6.5 4.0
24 13.0 8.0

High Pressure Fuel lines (5-12)

Caution: The high pressure lines must be clamped se-
curely and routed so they do not contact each other or
any other ~nlmnnn,~n1!~
The are and manufac-
tured to pressure to the
The pressure ........ ,.,..,., will cause the lines to
and contract cycle.
Shown here are the pressure fuel lines for distributor
pump.

Shown here are the high pressure fuel lines for the Bosch
in-line
Section 5 - Fuel Systems
B Series

Do not weld or substitute lines; use only the specified

part number for the engine.
The length, internal size and rigidity of the lines is critical
to smooth engine operation. An attached metal tag is
used to identify each line with a part number.

Caution: The pressure of the fuel in the line is sufficient

to penetrate the skin and cause serious bodily harm.
Use cardboard to check for cracks and leaks. With the
engine running, move the cardboard over the fuel lines
and look for fuel spray on the cardboard. Fuel leaks can
cause poor engine performance.

lt is normal to have entrapped air in the fuel lines after

replacing the pump or the lines. Air in the lines will cause
the engine to run rough or produce a fuel knock.

Bleed the air from the high pressure line at the that
connects the injector. Bleed one line at a time the
engine runs smooth.
If the air cannot be removed, check the pump and
line for suction leaks.

30

~--'---
[......_j
fs900S<

Tnewcamp Manuals
Injectors (5-13) Section 5 - Fuel Systems
Page 5-50 B Series

Injectors (5-13)
.tJ.. Caution: Use only the specified injector for the engine.
Part Number All engines use closed nozzle, hole-type injectors. How-
ever, the injectors can have different part numbers for
different engine ratings. The last four digits of the Cum-
mins part number are used to identify the injectors.

11901ga

During the injection cycle, high pressure from the injec-

High Pressure
line tion pump rises to the operating (pop) pressure which
causes the needle valve in the injector to lift. Fuel is then
injected into the cylinder. A shimmed spring is used to
force the needle valve closed as the injection pressure
drops below the pop pressure to seal off the nozzle after
injection.
Fuel Drain
Manifold

!1900kC

Failure of the needle valve to lift and close at the correct

High Pressure
line time or needle valve stuck open can cause the engine to
misfire and produce low power. Fuel leaking from the
open nozzle can cause a fuel knock, poor performance,
smoke, poor fuel economy and rough running.

fi900kd

To find which cylinder is misfiring, operate the engine and

loosen the fuel line nut at one injector and listen for a
change in engine speed.
A drop in engine speed indicates the injector was deliv-
ering fuel to the cylinder.
Check each cylinder until the malfunctioning injector is
found.
Be sure to tighten the fuel line nut before proceeding to
the next injector.
Section 5 • Fuel Systems Fuel Drain
B Series

Remove the malfunctioning injector to test or replace it.

If the engine continues to misfire after replacing the in-
jector, check for leaks in the high pressure line. Also
check for a defective delivery valve that lets the fuel drain
back into the injection pump.

Carbon build up in the orifices in the nozzle will also ~

cause low power from the engine. Remove and check the W
spray pattern or replace the injectors.

li900s.a

Fuel Drain Manifold (5-14)

The fuel system is designed to use fuel to cool and lu-
bricate the injection pump and injectors. Fuel is contin-
"""'''"''"''~"~ from the injection and a amount
leaks the valve
fuel is tank

Restriction of the fuel drain manifold can affect the Lucas

CAV DPAIDPS fuel injection pump metering controls and
the operation of the injectors. Restricting the fuel drain
manifold raises the case pressure of the fuel
pump which can prevent injection.
If the engine will restart after a waiting period an ~
unexplained shut down, look for a restriction of the man- ~
ifold drain line.
NOTE: Restriction can cause the fuel temperature to rise
reducing power from the engine.

Tnewcamp Manuals
Venting the Fuel Systems (5·1 Section 5 - Fuel Systems
Page 5-52 B Series

Venting the Fuel Systems (5-15)

Controlled venting is provided at the injection pump
through the fuel drain manifold. Small amounts of air
introduced by changing the filters or injection pump sup-
ply line will be vented automatically if the fuel filter is
changed in accordance with the instructions.

However, manual bleeding will be required if:

• The fuel filter is not filled prior to installation.
• Fuel injection pump is replaced.
• High pressure fuel line connections are loosened or
lines replaced.
• Initial engine start up or start up after an extended
period of no engine operation.

low Pressure lines and Fuel Filter - Venting

10 mm
the bleed screw.

the hand lever until the fuel flowing from the

is free of air.
the bleed screw.
Value: 9 N@lm ft-lb]
Section 5 • Fuel Systems Venting the Fuel Systems (5-15)
B Series Page 5-53

Injection Pumps - Venting

Air/fuel can be vented from the illustrated vent locations
on the Nippondenso EP-9 and the Lucas CAV fuel injec-
tion pumps. The Lucas CAV fuel injection pump requires
the fuel solenoid valve be energized before venting.
Loosen the vent screw and operate the priming lever on
the fuel transfer pump until fuel injection pump is primed.
Tighten the vent screw.

Caution: lt is necessary to put the engine in the "run"

position: Because the engine may start, be sure to follow
all the safety precautions. Use the normal engine start-
ing procedure.
Caution: When using the starting motor to vent the sys-
tem, do not engage it for more than 30 seconds at a time:
Wait two (2) minutes between engagements.
Air can also be vented through the fuel drain manifold line
by operating the starting motor.

fs900wj

High Pressure Fuel lines - Venting

17 mm, 19 mm
Caution: The pressure of the fuel in the line is sufficient
to penetrate the skin and cause serious harm.
Loosen the at the and crank the
to allow air to bleed from the line.

Caution: Do not bleed a hot engine as this could cause

fuel to spill onto a hot exhaust manifold creating a dan-
ger of fire.
Operate the engine and vent one line at a time until the
engine runs smoothly.

Tnewcamp Manuals
Fuel Filter = Reclacem Section 5 • Fuel Systems
5=54 B Series

Fuel Filter - Replacement (5-16)

80 to 95 mm, Filter Wrench
Remove the combination water separator/fuel filter.

80 to 95 mm, Filter Wrench

If used, remove the two filters from the dual filter adaptor.

24 mm, Flat Blade Screwdriver

If a leak is found, remove the dual filter adapter and
replace the o-rings.
Value: 32 N•m

the new with clean fuel.

lf9etwa
Section 5 - Fuel Systems Low Pressure Fuel Line Replacement - Distributor Pumps (5-17)
B Series Page 5-55

Lubricate the seal with clean lubricating oil.

ff9etwb

Caution: Mechanical tightening may distort the threads,

damage the filter element seal or filter can.
Install the filter as specified by the filter manufacturer.

91 model and newer automotive B series engines that are

equipped with the Bosch P7100 in-line fuel injection pump
have the fuel filter mounted at the rear of the intake
manifold as shown.

Pressure Fuel ne Replacement -

Distributor Pumps 7)
14 mm and 17 mm
Remove the line from the fuel transfer pump and fuel filter
head.

Tnewcamp Manuals
low Pressure Fuel line Replacement- Bosch P7100 Fuel Injection Pomp (5-18) Section 5 - Fuel Systems
Page 5-56 B Series

When replacing fuel lines, replace banjo fitting seal-

ing washers (1) each time they are removed.
~ Install the fuel line and tighten the fittings securely.

10 mm
Bleed the fuel line by opening the banjo bleed screw.

10 mm
Operate the hand lever until the fuel flowing from the
fitting is free of air.
the screw.

14 mm, 20 mm
Remove the from the piston style fuel transfer
pump.
Section 5 - Fuel Systems Low Pressure Fuel Line Replacement - Bosch P7100 Fuel
B Series

12 mm
Remove the fuel drain manifold line at the filter head.

17 mm
Remove the fuel line from the filter head.

17 mm, 12 mm, 14 mm, 20 mm

When replacing fuel lines, replace banjo sealing wash-
ers (1) each time they are removed.
the fuel line in the reverse order of ro:>nnrl\,rl:l

10 mm, 17 mm
Bleed the fuel line the banjo bleed screw.

Tnewcamp Manuals
Fuel Injection Pump Supply Line Replacement - Distributor Type Pumps (5·19) Section 5 - Fuel Systems
Page 5-58 B Series

10 mm, 17 mm
Operate the priming button on the fuel transfer pump until
the fuel flowing from the fitting is free of air.
Tighten the bleed screw.

Fuel Injection Pump Supply Line

Replacement - Distributor lYpe Pumps
(5-19)
17 mm
Remove the bleed screw banjo fitting and complete the
following steps.

14 mm and 17 mm
Remove the fuel line from the Bosch fuel injection pump
fitting.
NOTE: To prevent loosening the fuel inlet
use two wrenches when line.

14 mm, 16 mm, 19 mm and 24 mm

Remove the fuel supply line assembly from the two Lucas
CAV fuel injection pump fittings.
NOTE: Replace the seals in the fittings if the line is
disassembled.

ft9tbmj
Section 5 ~ Fuel ..::..,.,1t,,.....,,., Fuel
B

17mm
Install the fuel line in the reverse order of removal.
the fuel to fuel pump

Screw Value:

Operate the hand lever 10-20 strokes to fill the fuel

line.

9
copper washer

Tnewcamp Manuals
Fuel Transfer Pump Replacement • Diaphragm Style (5-21) Section 5 - Fuel Systems
Page 5-60 B Series

17 mm, 19 mm
Install in the reverse order of removal.

Fuel Transfer Pump Replacement -

Diaphragm Style (5-21)
Preparatory Step:
• Disconnect the low pressure fuel lines.

10 mm
Remove the fuel transfer pump and complete the follow-
ing steps.

ls900me

the surface on the block.

LI
ls9hseb
Section 5 - Fuel Systems Fuel Transfer Pump Replacement - Diaphragm Style
B Series Page

10 mm
Install the fuel transfer pump with a new gasket.
Torque Value: 24 N•m [18 ft-lb]

fs900hf

14 mm and 17 mm
Install the low pressure fuel lines.

10 mm
Open the banjo bleed screw to bleed the low pressure fuel
line.

10 mm
Operate the hand lever until the fuel flowing from the
fitting is free of air.
Tighten the bleed screw.

Tnewcamp Manuals
Fuel Transfer Pump Replacement/Rebuild - Piston Style (5-22) Section 5 - Fuel Systems
Page 5-62 B Series

Fuel Transfer Pump

Rebuild - Piston Style
Preparatory Step:
o Clean debris from the line and the fuel
transfer pump.

Removal
14 mm, 17 mm, 20 mm Wrench
Disconnect the fuel line from the fuel transfer pump and
fuel filter head.
Use two wrenches to disconnect the fuel line from the fuel
transfer pump.

10 mm
Remove the fuel transfer pump.
Clean the on block.

20 mm, 26 mm Wrench
are
Hand Prime can
Fitting

ER~ to
Remove the
the three illustrated

ls9hsea
Section 5 - Fuel Systems Fuel Transfer Pump Replacement/Rebuild - Piston
B Series

Remove all internal components ofthe fuel transfer pump.

NOTE: Make sure the check valve gaskets are removed from
the inlet fitting.
(A} Outlet Fitting(B) Inlet Fitting
(B) Inlet Fitting
(C) Hand Primer Fitting

Cleaning
Thoroughly flush the fuel transfer pump with a cleaning
solution to remove any debris.

ls900ea

Assembly
20 mm, 26 mm Wrench
Assemble the fuel transfer with the new compo-
nents supplied in the
1. valves
2. valve ui':!:sKt~t:s
3. seal
4. Outlet
5. *0-ring
6. *0-ring seal or
* 0-ring required is determined the size of the inlet
fitting. Discard unused o-ring.

Extreme must be used to make sure the

check valves are installed to open in the direction of the fuel
flow.
Improper installation of the check valves will result in low
power from the

Tnewcamp Manuals
High Pressure Fuel Line Replacement • Distributor Type Pumps (5-23) Section 5 • Fuel Systems
Page 5-64 B Series

Place the fuel transfer pump in a vise and torque the

fittings to the following values:
(A) Outlet Fitting 30 N•m [22 ft-lb]
(B) Hand-Prime Fitting 30 N•m [22 ft-lb]
(C) Inlet Fitting 30 N•m [22 ft-lb]

fs900wb

Installation
10 mm
Caution: Alternately tighten the mounting capscrews.
As the capscrews are tightened the fuel transfer pump
plunger is pushed into the pump. Failure to tighten the
capscrews in an even manner can result in the plunger
being bent or broken.
Install the pump.
Torque Value: 24 N•m [18 ft-lb]
fs900hb

14 mm, 17 mm, 20 mm Wrench

Install the fuel line to the fuel transfer pump and fuel filter
head. Use two wrenches to tighten the connection to the
pump.
24 N•m [18
Refer to 5-15 for low pressure fuel

High Pressure Replacement

.. Distributor Type Pumps (5-23)
17 mm
Disconnect the high pressure fuel lines from the injectors
and complete the following steps.
NOTE: Thoroughly clean area around fuel lines before
removal.
Section 5 - Fuel Systems High Pressure Fuel Line Replacement - Distributor Type Pumps (5-23)
B Series Page 5-65

10 mm
Remove the fuel line clamp capscrews from the intake
cover.

14 mm and 17 mm
Remove the fuel lines from the fuel injection pump.
NOTE: Use two wrenches to prevent the delivery valve holder
from turning.

10 mm
Assemble the fuel lines in the reverse order of removal.
Torque Value: 30 N•m [22 ft-lb]

Do not bleed a hot engine as this could cause

fuel to spill onto a hot exhaust manifold creating a dan-
ger of fire.
Operate the engine and vent one line at a time until the
engine runs smoothly.

Tnewcamp Manuals
High Pressure Fuel Line Replacement • Bosch P7100 Pump (5·24) Section 5 - Fuel Systems
Page 5-66 B Series

High Pressure Fuel Line Replacement

• Bosch P7100 Pump (5-24)
Preparatory Steps:
• Clean debris.

19 mm
NOTE: If individual fuel lines are to be replaced, remove the
support clamp from the set of fuel lines containing the line
to be replaced.
Disconnect the fuel line(s) from the injectors.

10 mm
Remove the fuel line clamp capscrews from the intake
cover.

19 mm
Disconnect the fuel line(s) from the fuel injection pump.
Section 5 • Fuel Systems Fuel Drain Manifold Replacement • Distributor Type Pumps (5-25)
B Series Page 5-67

If removed, reinstall the support clamp in the original

position and make sure the lines do not contact each.
other or another component.
Loosen the vibration isolator capscrews so the fuel lines
can be easily moved.
NOTE: To prevent breakage to the fuel lines, they must be
connected to the injector and fuel injection pump in a "free
state" without forcing the connecting nuts. Since the fuel
lines are properly sized for specific application, bending
should not be necessary.
Install the fuel lines in the reverse order of removal.
Torque Value:
(Line Fittings) 30 N•m [22 ft-lb]
(Support Clamp) 6 N•m [ 4 ft-lb]
(Support Bracket) 24 N•m [18 ft-lb]
NOTE: The inside holes of the intake manifold are drilled
through and require liquid teflon sealant.

Fuel Drain Manifold Replacement -

Distributor Type Pumps (5-25)
10 mm
Remove the capscrews from the hold-down clamps and
complete the following steps.

10 mm
Remove the screws and washers.

Tnewcamp Manuals
Fuel Drain Manifold Replacement - Distributor Type Pumps (5-25) Section 5 - Fuel Systems
Page 5-68 B Series

17mm
Disconnect the fuel drain line fittings.

Assemble the fuel drain line and fuel drain manifold in the
reverse order of disassembly.
NOTE: Use new seals for the fittings .

.····r. .
....~...~.

i . ..-<::·:::~:::::::
..................
~~~::

ft9tbhg

The installation torque for the banjo fitting screw is 9 N•m

[7 ft-lb].
NOTE: Use new sealing washers for the fuel drain manifold.

!t9waha

The installation torque for the clamp capscrews is 24 N•m

[18ft-lb].
Section 5 - Fuel Systems Fuel Drain Manifold Replacement - Bosch P7100 (5-26)
B Series Page 5-69

Fuel Drain Manifold Replacement -

Bosch P7100 {5-26)
Preparatory Steps:
• Clean debris.

10 mm, 12 mm
Remove the banjo capscrews and copper sealing wash-
ers at the fuel filter head.
Remove the fuel line support bracket capscrew from the
intake manifold.

10 mm
Remove the banjo capscrews and copper sealing wash-
ers from the injectors.
Install the fuel drain manifold in the reverse order of re-

Value:
~ Injector Banjo 9 N~m [ 7ft-lb]
e Fuel Filter Head 13 N•m [10 ft-lb]
NOTE: The fuel line support bracket capscrew in the intake
manifold requires liquid teflon sealant

Pressure Relief Valve Replacement-

Bosch P7100 (5-27)
19 mm
Remove the pressure relief valve and copper sealing
washer.

Tnewcamp Manuals
Air Fuel Control Tube Replacement - Bosch VE Pump (5-28) Section 5 • Fuel Systems
Page 5-70 B Series

Use a small screwdriver to chec~k that the check ball is not

sticking in the high pressure relief valve assembly.
Caution: A sticky check ball will result in engine low
power.

fs9cbsa

Thoroughly flush the high pressure relief valve with clean-

ing solution.

fs9vaea

10 mm, 19 mm
Install the high pressure relief valve assembly in the re-
verse order of removal.

12 mm, 1/2 inch

Remove fuel tube from the and
the pump.
Use new sealing washers when installing the tube.
~ Assemble in the reverse of removal.

le9tbma
Section 5 - Fuel Systems Air Fuel Control Tube Replacement - Bosch P7100 Pump (5-29)
B Series Page 5-71

Air Fuel Control Tube Replacement -

Bosch P7100 Pump (5-29)
13 mm
Remove the AFC tube.

Inspect the rubber sealing washers and replace as

necessary.

ft9wasa

Install the AFC tube in the reverse order of removal.

Torque Value: 24 N•m [18 ft-lb]

Fuel Shut Off Valve Replacement ..

Bosch VE (5-30)
8mm
Remove the electrical wire and complete the following
steps.

fv900mb

Tnewcamp Manuals
Fuel Shut Off Valve Replacement • Bosch VE (5·30) Section 5 • Fuel Systems
Page 5-72 B Series

Clean around the valve.

24mm
Remove the valve.
NOTE: The Bosch VE valve is shown. The valve for Lucas
CAV is located at the bottom of the pump.

Caution: When removing the valve, be careful not to

drop the plunger and spring.

~ "Package" the solenoid, o-ring, spring and plunger.

~
Section 5 - Fuel Systems Fuel Shut Off Solenoid Adjustment/Replacement- Bosch P7100 (5-31)
B Series Page 5-73

24mm
Tighten the solenoid securely.
Connect the electric wire.
Torque Value: 43 N•m [32 ft-lb]

Fuel Shut Off Solenoid Adjustment/

Replacement- Bosch P7100 (5-31)
Preparatory Steps:
• Label and disconnect the wiring.

10 mm
Remove the two hold-down capscrews and clip pin.
Remove and replace the fuel shut off solenoid.
Value: 9 N•m

Adjustment
Refer to Procedure (5-11), Shut Down Solenoid (In-Line
Type Injection Pump)- Troubleshooting, for troubleshoot-
ing the solenoid.
Turn the key to the "on" position. This will energize the
red (hold) wire and black (common) wire.
This is the low current hold-in coil and must be energized
continuously during this adjustment.
NOTE: Do not turn the key to the "run" position at this time.
This will energize the white (pull-in) wire.

Tnewcamp Manuals
Fuel Shut Off Valve Replacement Stanadyne DB4 (5-32) Section 5 - Fuel Systems
5-74 B Series

Move the shutoff lever by hand to the full run position.

10 mm, 16 mm
Check the plunger travel.
A = 66.9 mm [2.64 in] maximum
NOTE: Dimension A is measured from the bottom of the
mounting bracket to the top of the pivot pin.
Adjust the solenoid linkage as necessary so that the
plunger is magnetically held in now with the shutoff lever
in the absolute full run position. Turn the large hex on the
end of the plunger to make adjustments.

Fuel Shut Off Valve Replacement

Stanadyne DB4 (5-32)

® Remove the """'''"'"'''"'

• Remove the fuel drain line.
• the
® the fuel
"' the fuel cover.

ip!lcvmc

5/16 Inch
Install new insulating tubes onto the on the
terminal studs of new solenoid.
Install the valve into the cover.
Value: 14 Nom [12
Section 5 - Fuel Systems Back Leakage Valve and Sealing Washer {lucas CAV DPA) - Replacement (5-33)
B!O::o=om•i"'"'l Page 5-75

5/16 Inch
Install the cover and gasket onto the fuel injection pump.
With the tool installed as shown, place the cover in po-
sition on the pump housing. Twist the tool to release it and
slide it out from between the cover and the housing.
Extreme care must be taken in assembling the cover
to a fuel pump to make sure the shutoff arm is in
proper contact with the linkage hook tab.

In the event that the service tool is not available, the

governor cover should be installed as follows:
Move the shut off lever to the stop position.
Install the cover to pump at a downward angle from the
drive shaft end of the fuel injection pump, then slide the
cover horizontally into position.
Torque Value: 4.6 N•m in-lb[

valves are installed

need to removed
block.

16 mm
Remove the valve.

fp9vamb

Tnewcamp Manuals
Back Leakage Valva and Sealing Washer (Lucas CAV DPA) • Replacement (5-33) Section 5 - Fuel Systems
5-76 B Series

Inspect the valve to be sure it is not stuck.

fp9vasb

Inspect the sealing surfaces for possible leak paths.

lp9vasa

16 mm
Caution: The installation torque is very critical. Over-
tightening can distort the bore in the pump hydraulic
head causing the rotor to seize In the bore. Never tighten
the valve with the engine
the back '"'"''"""'-'
the valve to 30

lp9vaab

17 mm
Connect the high pressure line.
Section 5 • Fuel Systems External Pump Leaks (Distributor Type Pumps) • Repair (5·34)
B Series Page 5-77

Start the engine and vent one line at a time until the
engine runs smoothly.

External Pump leaks (Distributor Type

Pumps) .. Repair (5-34)
Make sure that the surrounding area is clean before
removing the leaking part.
NOTE: Accessible sealing washers and gaskets can be re-
placed without removing the pump.
Refer to the Shop Manual, Bulletin 3810206 for additional
information.

Pump Replacement
Pumps)

• Disconnect the
• Remove the
• Remove the pressure lines.
• Disconnect electrical wire to fuel shut off
valve.
• Remove the fuel air control if used.

Caution: Do not remove the control lever. The Bosch VE

lever is to the shaft calibration.
Disconnect all control

Tnewcamp Manuals
Fuel Injection Pump Replacement (Distributor Type Pumps) (5•35) Section 5 - Fuel Systems
Page 5-78 B Series

-l
-
13 mm
Remove the pump support bracket.

22 mm
Remove the access cap and gear retaining nut and
washer.

Be sure to disengage the after TDC.

Locate TDC for No. 1

9/16 inch
Loosen the CAV fuel
sition the
the pump drive
Value: 7 N•m [5

1 locked ~t-
r-~~-
~ Small Openin!
\~Showing
' !s91oue
Section 5 - Fuel Systems Fuel Injection Pump Replacement (Distributor Type Pumps) (5-35)
B Series Page 5-79

3/8 Inch
Loosen the Stanadyne DB4 fuel injection pump lock screw Locked ~
and position the special washer. Tighten the lock screw

~\'
until contact is made with the fuel injection pump drive
shaft.
Torque Value: 12 N•m [9 ft-lb]

ip9waha

8 mm Alien Wrench or 10 mm Hex

The special washer on the Bosch injection pump must be
removed so the lock screw can be tightened against the
drive shaft.
Torque Value: 30 N•m [22 ft-lb]
NOTE: Wire the washer to the pump.

75 mm T-Sar
Pull the fuel injection pump drive gear loose from the
pump drive shaft.

fs9gema

13 mm
Do not gear key when removing the pump.
Remove the 3 mounting nuts and take off the fuel injection

Tnewcamp Manuals
Fuel Injection Type Pumps) (5-35) Section 5 • Fuel Systems
5-80 B Series

Et;~ Remove the gasket and clean the surface.

. ·~·-.
/ ..
' .
'

·, .........~

gh9haea

Installing the Pump

Verify Cylinder No. 1 is at TDC by barring engine slowly
while pushing in on TDC pin.

~ Install a new gasket.

'"W

fpSgkha

The drive shaft must be clean and free of all oil

Failure to ensure the drive is
of oil can result in drive gear on the
shaft.
lll.lt''\Tf::. The shaft of a new or ror•nnrliti pump is
with the ki'!\N\ft::lv when

on the
Make sure the does not fall into the
Section 5 - Fuel Systems Fuel Injection Pump 1eD1acemem: (Distributor Type Pumps) (5-35)
B Series Page 5-81

Use your hands to tighten the three mounting nuts. The

pump must be free to move in the slots.

22 mm
Caution: Do not overtighten. This is not the final torque.
Install the pump drive shaft nut and spring washer. The
pump will rotate slightly because of gear helix and clear-
ance. This is acceptable providing the pump is free to
move on the flange slots and the crankshaft does not
move.
Torque Value: 15 to 20 Nem to 15

13 mm
rotate the pump to the

Value: 24 Nem [18

Value: 24 Nem

Tnewcamp Manuals
Fuel Injection Pump Replacement (Distributor 1\lpe Pumps) (5·35) Section 5 - Fuel Systems
Page 5-82 B Series

Permanently mark the injection pump flange to match the

mark on the gear housing.

9/16 inch
Loosen the CAV pump lockscrew and position the special
washer behind the lockscrew head.
~ Torque Value: 20 N•m [15 ft-lb]

3/8 Inch
Loosen the Stanadyne DB4 fuel injection pump lock screw
and position the special washer behind the lock screw
head.
the lock screw.

8 mm Alien or 10 mm Hex
On the Bosch pump, the special washer is wired to the
pump and must be installed under the lockscrew.
Torque Value: 13 N•m [10 ft-lb]
Section 5 - Fuel Systems Fuel Injection Pump Replacement (Distributor Type Pumps) (5·35)
B Series Page 5-83

Disengage the timing pin before rotating the

crankshaft.

10 mm
Install the injection pump support bracket. Finger tighten
all capscrews before final tightening.
NOTE: Tighten the bracket to block mounting capscrew
before tightening the bracket to injection pump capscrews.

22 mm
the nut.
Value: Bosch 65 N•m [48
"'""''""',.."'' 65 N•m

fp9nuhe

Tnewcamp Manuals
Fuel Injection Pump Replacement (Distributor Type Pumps) (5·35) Section 5 - Fuel Systems
Page 5-84 B Series

~ Install the access cap.

~

8mm
Install all fuel lines and the electrical wire to the fuel shut
off valve.

12 mm and 1/2 inch

If required, install the air fuel control tube.

When connecting the cable/rod to the control lever, adjust

the length so the lever has stop-to-stop movement
Section 5 - Fuel Systems Fuel Injection Pump Timing (5-36)
B Series Page 5-85

Adjust the length of the cable or rod to the mechanical ~

shut down lever so there is stop-to-stop movement. ®

I
I
!/

Bleed all air from the fuel system.

Refer to Procedure (5-15).

If necessary, adjust the idle speed.

LUCAS CAV BOSCH VE STANADYNE

Fuel Injection Pump Timing (5 ..36)

Pump-to-engine timing is extremely critical. Pump timing
that is off by only a few crankshaft degrees will cause:
1. Poor performance - starting and power.
2. Excessive smoke and emissions.
3. Poor fuel economy.

Tnewcamp Manuals
Fuel Injection Pump Timing (5-36) Section 5 • Fuel Systems
Page 5-86 B Series

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 No. 1.
Then, depending on the engine configuration, a letter on
the gear may need to be aligned with the mark on the
camshaft gear.

Lane< on
This table must be used to make sure of proper fuel
Pump Gear Engine Model Injection Pump Certlncatlon injection pump-to-engine timing. The critical parts list
A 4B3.0,48T3.t Slonodyne Non..Certltled (CPL) number from the engine data plate and the Control
A 483.8, 4BT3.t, 4BTAU Luca• CAV DPA Pump All Non.Certlflod
11 4BU.4BTAU Robart Boech VE Pump 8U7EPA Parts List Manual, Bulletin No. 3379133-20, must be used
All pro-88
All Non.Certmed to determine whether or not the engine is certified, and
c ii8T5.t1 IITA$.8 Rober Boach VE Pump H.I7EPA
if so, what year and regulating agency (EPA or CARB).
AUpr...a&
All Non-Certified
CPLIOO
D eBU.GIITIU Stanadyne NonoCettillod Given this information, use the following table to deter-
L.uoas.cAV OPA Pump All Non.CenHied
D
11!
685,9, SBTS.e, 88TAS.9
SBTI.81 88TAI.t Rober liSosch YE Pump 8810'7,18,89,90.11," CARB mine which letter on the fuel injection pump drive gear is
48T3.8, 48TA3.1 Rober Boeeh VE Pump
38.80,90.11,12 EPA
H,81,U.8t,80,t1,12 CARS
aligned with the camshaft gear.
~tl,to,D1,t21EPA
G 611TAU LUOII&CAVDPA All Flto Pump
CPL 1115
NOTE: Timing mark alignment is not required for the Nip-
H No!UH<IatT!IIOTIIIMI pondenso EP-9 or Bosch P7100 drive gear.
lt900ga

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 mark will advance
orretard on the pump
1

and the
a provision for
co"n·esponding to
1. New and recondi-
should be received with the
Section 5 - Fuel Systems Fuel Injection Pump Timing (5-36)
B Series Page 5-87

At the point of injection the key way of the shaft will align
with the delivery valve receiving the injection, and the
illustrated hash mark on the seal housing.
NOTE: The illustrated mark is for reference only and should
not be used for setting the fuel injection pump timing.

The number one cylinder delivery valve is marked as

i 11 ustrated.
4 cylinder = A
6 cylinder = D
Firing Order
4 Cylinder 6 Cylinder
A =1 D =1
B =3 E =5
c =4 F =3
D =2 A =6
B =2
c =4

The engine is equipped with an engine timing pin to

locate TDC for Cylinder No. 1.

Caution: If the timing pin is incorrectly located on the

gear housing, the timing procedure will not ensure that
the pump is timed correctly.
After precisely locating TDC for Cylinder No. 1, the factory Pin
positions the timing pin assembly to the gear housing
using the timing pin and the hole in the camshaft gear. If
the gear housing ortiming pin assembly are removed, the
same precision is required to relocate it. Refer to Proce-
dure (7-20).
If the timing pin assembly is incorrectly located, reposi- ~
tion the timing pin. Refer to Procedure (7-20).
cg9gewa

Tnewcamp Manuals
Fuel Injection Pump Timing (5·36) Section 5 • Fuel Systems
Page 5-88 B Series

The flange of a replacement pump must be marked to

align with the mark on the gear housing after instal·
lation.
During production, after the locked pump is fitted to the
engine with Cylinder No. 1 at 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.
The marks on the gear housing and the pump flange
are unique to each engine.

A special indicator can be used to measure the position

of the Robert Bosch VE fuel injection pump plunger to
#1 check pump timing.
TDC Refer to Timing Check - (Bosch VE Pump) - Procedure
(5-36).

[2J
)i
Timing
Clean all from around the fuel injection pump tim-
window cover.

Remove the cover.

Section 5 - Fuel Systems Fuel (5-36)
B Series 5-89

Rotate the fuel injection pump drive shaft in the direction

of pump rotation to align the timing line on the weight
retainer hub with the line on the cam ring.
Q

Position the fuel injection drive shaft locking key plate in

the locked position. Turn the locking screw in until contact Locked
is made with the drive shaft.
on.-. ...... Value: 11.9 N•m [105 in-lb]

the marks are aligned after lock timed.

Install the fuel pump cover.

Tnewcamp Manuals
Fuel Injection Pump Timing (5·36) Section 5 - Fuel Systems
Page 5-90 B Series

CAV DPA/DPS Fuel Injection Pump Timing

Correct timing of the Lucas CAV DPA/DPS fuel injection
pump can be verified by removing the inspection plate.
NOTE: Special equipment in an authorized shop is required
to precisely time the Lucas CAV DPA fuel injection pump.
However, for troubleshooting and in an emergency, visual
alignment of the timing mark is close enough for the engine
to run.
Both of these checks are described in the fuel injection
pump replacement discussion. Installation of the timing
pin housing is described in the Base Engine Components
Section.

Timing Check - (Bosch VE Pump)

Rotate the crankshaft to TDC.

12 mm
Remove the plug from the end of the pump.

3377259 Timing Indicator

1 Rotation Caution: Do not bend the fuel lines.
Install the timing indicator. Be sure to allow adequate
travel for the indicator.
In order to install the timing indicator, it may be necessary
to disconnect one or more of the fuel lines from the fuel
pump.
NOTE: The indicator is marked in increrr...:mts of 0.01 mm.
One revolution of the indicator needle is equal to 0.50 mm.
0.50 mm
fp9towa
Section 5- Systems Injection Pump Timing (5-36}
B Series Page 5-91

Bar the crankshaft in the direction opposite engine rota- (5)')

tion until the indicator needle stops moving. Adjust the W
indicator face to read zero.
Rotate the crankshaft back to TDC and count the number
of revolutions of the indicator needle. The reading shown
when the engine timing pin engages is the amount of
plunger lift the pump has at that point.

13 mm
Rotate the pump on the mounting studs until the indicator
reads the correct value for plunger lift. This illustration
gives an example of the indicator readings for the various
plunger lift values.
Tighten the flange mounting nuts.
Torque Value: 24 N•m [18 ft-lb]

12 mm
Remove the indicator. Install the
Value: iO Ne~m

Rotate the to TDC.

Tnewcamp Manuals
Fuel Injection Pump Timing (5-36) Section 5 - Fuel Systems
Page 5-92 B Series

Correct timing of the Lucas CAV DPA and Stanadyne DB4

fuel injection pump can be verified by removing the timing
window cover plate.
The Nippendenso EP-9 and Bosch P-7100 fuel injection
pumps are checked by removing the timing pin access
plug and verifying the slot in the pin will fit over the timing
tooth in the fuel injection pump.
NOTE: Special equipment in an authorized shop is required
to precisely time the Lucas CAV DPA fuel injection pump.
However, for troubleshooting and in an emergency, visual
alignment of the timing mark is close enough for the engine
to run.
To correct the timing on the Bosch P-7100 and Nippen-
denso EP-9 refer to the replacement procedure for the
respective pump.

Two injection pump timing marks are used on the Stana-

dyne DB4 for timing injection of fuel into the No. 1 cyl-
inder. One mark is located on the governor weight retainer
hub. The other is located on the internal cam ring. These
two marks must be aligned at No. 1 cylinder Top Dead
Center.

On the Lucas CAV DPA the correct letter can be

located on the engine data plate as ..,n.-uAtn

The letter G refers to the correct letter

as in the frame.

ap9p!wb
Section 5 - Fuel Systems Fuel Injection Pump Timing (5-36)
B Series Page 5-93

In-line Fuel Injection Pump Spill-Port Timing

Use the No. 1 intake valve to make sure the engine is at ~
top dead canter (TDC) on the compression stroke for
cylinder No. 1. Refer to page 7-141.

er900wl

Fabricate a timing mark pointer for the front of the engine.

This can be done by forming a piece of wire that can be
tightened under one of the gear cover capscrews. Sharpen
the wire at the vibration damper end so that it comes to
a point for better accuracy.

er900wm

Attach a degree wheel or degree tape to the front of the

vibration damper.
Line the "TDC" mark up with the pointer.
The degree wheel/tape should measure to an of
at least one degree.

Install the fuel injection pump per the procedures for a

new fuel injection pump installation. If the fuel injection
pump is already installed, continue

Tnewcamp Manuals
Fuel Injection Pump Timing (5-36) Section 5 - Fuel Systems
Page 5-94 B Series

Remove the No. 1 high pressure fuel line from the fuel
injection pump.
NOTE: Lines 2 through 6 must not be removed or loosened.

Caution: When attaching the fabricated tube, do not

bend the No. 1 high pressure fuel line. This could cause
the inside of the fuel line to flake and cause injector
failure.
A short length of high pressure line that is compatible with
the fuel lines used on the engine should be bent in a "U"
shape and installed onto the delivery valve holder of the
fuel injection pump. The line is used to observe when the
fuel is or is not flowing through the delivery valve holder
assembly. Place a container under the tube to catch the
fuel or drain the fuel back into the spill port pump.

Remove the overflow valve from the fuel injection pump.

Install a 14 mm threaded plug and sealing washer into the
fuel return port of the fuel injection pump.
The fuel return port is located on the inboard front
side of the fuel injection for in-line
on the front side for most of

Remove the supply line from the fuel filter to the

injection pump.
Attach the high pressure outlet hose from the to
the fuel injection pump supply port.
Section 5 - Fuel Systems Fuel Injection Pump Timing (5-36)
B Series Page 5-95

Before continuing, make sure the fuel injection pump

lock-timing pin is disengaged.

Rotate the crankshaft counterclockwise, as viewed from ~

the front of the engine, to approximately 40 degrees be- ~
fore TDC.

Governor lever Positioning

Caution: The governor lever must be positioned before
pressurizing the fuel injection pump.
lever must in the low idle

Both the RQV and governor require the shut down

lever to be in the full run position.

lp900wp

Tnewcamp Manuals
Fuel Injection (5-36) Section 5 • Fuel Systems
Pegs 5-96 B Series

The RVS governor throttle lever must be in the low idle

position and the shutdown lever needs to be wired or
locked in a suitable fashion to hold the shutdown lever in
the 112 travel position.

Turn on the spill timing cart pump.

Check the fuel pressure.
The pressure must be between 300 psi and 370 psi.

The fuel should be flowing out of the tube attached to the

No. 1 cylinder of the fuel injection pump. If the fuel is not
flowing, recheck the procedures carefully.

Slowly rotate the crankshaft in the as

viewed from the of the engine, until the fuel flow from
No. 1 cylinder begins.
No. 1 plunger element is now
closure". Continue to rotate the
flow is reduced to a fast drip (more than one
second.) At the point where the steady stream
changes from a solid flow to a fast stop.
static position of the fuel pump.
Section 5 - Fuel Systems Fuel Injection Pump Timing (5-36)
B Series Page 5-97

If the flow does not slow down to a drip, check the gov- ~
emor position. Also make sure that the engine is before ~
TDC on the compression stroke.
Turn off the spill port pump.

Check the degree wheel on the vibration damper to see

what engine degree the timing pointer is indicating. This
~
~
___.. . .-
~!)
t;J)
~

is spill port static timing. Compare this number to the

timing specification for your particular application.

If the fuel injection pump static timing, as measured by

the above method, does not agree with the specifications
have been given, remove the large nut that fastens
injection camshaft to the fuel pump drive
If the rotated, turn on the spill port
rotate the to find
the pump.

Use a gear the fuel injection pump drive Q~

from pump camshaft taper. \I:>~

Tnewcamp Manuals
Fuel Injection Timing (5-36) Section 5 - Fuel Systems
Page 5-98 B Series

Slowly rotate the crankshaft counterclockwise about 40

degrees pastthe desired static timing specification. Slowly
rotate the crankshaft in the clockwise direction until the
timing pointer is indicating the desired static timing.

Tighten the fuel injection pump drive nut.

Make sure the static timing has not changed after the fuel
injection drive nut is torqued to the required specification.
Torque Value:
PES6A Fuel Injection Pump 92 N•m [ 68 ft-lb]
PES6MW Fuel Injection Pump 104 N•m [ 77 ft-lb]
PES6P Fuel Injection Pump 165 N•m [122 ft-lb)

Repeat this procedure as needed until the timing is found

to be in agreement with the specification.

The fuel injection pump lock timing pin should fit over the
injecting pump pointer when the engine is. at TDC or on
the compression stroke for the No. 1 cylinder. If it does
not, the fuel injection pump should be adjusted by an
authorized fuel injection pump shop or the fuel injection
pump was installed incorrectly.
Section 5 - Fuel Systems Fuel Injection Pump Replacement (In-line) (5-37)
B Series Page 5-99

Fuel Injection Pump Replacement

(In-line) (5-37)
Bosch P7100
Preparatory Steps:
• Clean debris.
• Disconnect all fuel lines to the pump.
• Remove control linkage.
• Disconnect AFC tube.
• Disconnect waste-gate turbo control line.

Removal
9/16
Disconnect the external oil feed line at the inboard side
of the fuel injection pump and the main oil rifle.

Locate TDC for Cylinder No. 1. Push the TDC pin into the
hole in the camshaft gear while slowly barring the engine.
NOTE: Be sure to disengage the timing pin after locating
TDC.

10 mm
Remove the fuel injection pump mounting bracket.

Tnewcamp Manuals
Fuel Injection Pump Replacement (In-line) (5-37) Section 5 - Fuel Systems
Page 5-100 B Series

30mm
Remove the gear cover access cap.
Remove the nut and washer from the fuel injection pump
shaft.

gc9cama

T-Bar Puller
Pull the fuel injection pump drive gear loose from the
shaft.

fs9gema

15 mm
Remove the four mounting nuts.
Remove the fuel injection pump.

Installation
Make sure the engine has Cylinder No. 1 at
Section 5 - Fuel Systems Fuel Injection Pump Replacement (In-line) (5-37)
B Series Page 5-101

The fuel injection pump also has a timing pin (1), located
in the governor housing, to position the pump shaft to
correspond with TDC for Cylinder No. 1. The pin is to be
reversed and stored in the housing (2) after the pump is
installed.

24mm
Remove the access plug.

Remove the timing pin.

If the timing tooth is not aligned with the timing pin hole,
rotate the fuel injection pump shaft until the timing tooth
aligns.

Tnewcamp Manuals
Fuel Injection Pump Replacement (In-line) (5-37) Section 5 • Fuel Systems
Page 5-102 B Series

Reverse the position of the timing pin so the slot of the

timing pin will fit over the timing tooth in the pump.
Install and secure the timing pin with the access plug.

Use a 50/50 mixture of clean engine oil and STP or

equivalent to lubricate the gear cover housing to ensure
the fuel injection pump will slide into the gear cover hous-
ing easily.

Also lubricate the mounting flange of the fuel injection

pump.
NOTE: The P7100 fuel injection pump driveshaft has a pro-
vision for a Woodruff key, however, it is not required. Timing
mark alignment is not required for the P7100 drive gear.
Caution: The fuel drive gear di-
ameter and the shaft outside must be clean and
before installing the gear.

Slide the pump shaft through the drive gear and position
the pump flange onto the mounting studs.
Push the pump forward until the mounting flange and
o-ring are properly fitted into the gear housing bore.
Section 5 - Fuel Systems Fuel Injection Pump Replacement (In-line) (5-37)
B Series Page 5-103

Do not attempt to pull the pump flange into the gear

housing with the mounting nuts as damage to housing will
occur.

15 mm
Install the mounting nuts.
Torque Value: 43 N•m [32 ft-lb]

30 mm
Install the retaining nut and washer.
Torque Value: 10 to 15 N•m [7 to 11 ft-lb]
To prevent damage to the timing pins, do not exceed the
value
Tnrr" ''"' This is not the value for
nut.

Disengage the engine timing pin.

Tnewcamp Manuals
Fuel Injection Pump Replacement (In-line) (5-37) Section 5 - Fuel Systems
Page 5-104 B Series
24mm
Remove the fuel injection pump timing pin plug, Reverse
the position of the timing pin and install the timing pin,
plug, and sealing washer.
Torque Value: 15 N•m [11 ft-lb]

30 mm
Tighten the fuel injection pump drive nut.
Torque Value: 165 N•m [122 ft-lb]
Install the gear cover access cap hand tight.

10 mm
Install the fuel injection pump mounting cap-
screws.
Tighten all capscrews to ensure proper
ment.
24

Install the fuel lines, AFC

charger wastegate line.
Torque Values:
High Pressure Fuel Lines
Low Pressure Fuel Supply
Section 5 = Fuel Systems - Bosch P7100 (5-38)
B Series Page 5-105

9/16 in
Install the external oil feed line at the inboard side of the
fuel injection pump and the main oil rifle.

19 mm
Caution: The pressure of the fuel in the high pressure
line is sufficient to penetrate the skin and cause serious
bodily harm.
Vent the high pressure fuel lines. Loosen the fitting at the
number 1 injector. Place the fuel control in the run posi- OFF
tion. Crank the engine so air can bleed from the fuel lines.
Then, tighten the fitting.
Value: 30 N•m [22 ft-lb] ®

Vent each high pressure line separately until the engine

runs smoothly.

on the Bosch P7100 can be made

idle screw ) and turning the idle
the desired speed.

Tnewcamp Manuals
Idle Speed Adjustment - Distributor Pumps (5-39) Section 5 - Fuel Systems
Page 5-106 B Series

Turn the screw down (clockwise viewed from top) to de-

crease idle sped.
Turn the screw up (counterclockwise viewed from top) to
increase idle speed.

After the desired idle speed is obtained, tighten the

locknut.

STANADYNE
Idle Speed Adjustment .. Distributor
Pumps {5-39)
10 mm
screw locknut and the idle as

Steps:
(I) Clean around the injectors.
• Disconnect the high pressure fuel lines.
"' Disconnect the fuel manifold.
Section 5 - Fuel Systems Injector - Replacement (5-40}
B Series Page 5-107

Rust Penetrating Solvent

Caution: When rust has formed on the hold down nut,
the injector can turn in the bore when the nut is loos-
ened. This will cause severe damage to the head by the
injector locating ball cutting a groove in the bore.
Soak the hold down nut with a rust penetrating solvent for
a minimum of 3 minutes.

Brass Drift Pin, Hammer

Hit the injector body with the drift pin to loosen any rust.

. ----. ----- li900we

24 mm Box Wrench, Adjustable Wrench

Hold injector body with an adjustable wrench while
you loosen the hold down nut with a 24 mm box wrench.

nu•·~uu· Puller
Remove the An injector puller is available for
to remove injectors.

Tnewcamp Manuals
Injector • Replacement (5-40) Section 5 - Fuel Systems
Page 5-108 B Series

lt may be necessary to tap the injector with the injector

puller to work the injector up and down in order to remove
it.

Injector Bore Brush 3822509

Clean the injector nozzle bore.

,--. fl9boea

Assemble the injector and new copper sealing washer.

Use only one copper washer.
Service Tip: A light coat of clean 15W40 engine oil be-
tween the washer and injector can to keep the washer

fi9waaa

model injectors (pre 1 have a 9 mm

cannot be used in engines built in 1991
9mm 7mm or later as these engines use a 7 mm injector

!1901gb
Section 5 - Fuel ""'· ··~......... (5-40)
B Series 5-109

9mm 7mm li900wl

a coat of anti-seize compound to the threads of the

hold down nut and between the of the nut and
body.

fillnuwa

24 mm
Caution: with the notch
in bore.
Value: 60 N@m

Tnewcamp Manuals
Injector - Replacement
Page 5-110

17 mm, 19 mm
Caution: lt is necessary to the in the "run"
POSit liOn Because the engine start, be sure to follow
the safety Use normal start-
procedure.
Crank the engine to allow air to bleed from the
lines. Tighten the fittings.