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Contrails ! Bosch VE injection pump

bosch pump

 

Homebuilts and Diesel

Homebuilders show much interest in Diesel engines : after developing the Dieselis with Paul Lucas, Serge Pennec designed the Gaz'Aile.

This aircraft was largely drawn from the Banbi-MCR familiy, with an inexpensive engine.

Reconditionning a Bosch injection pump

Bricofoy is a young electronics engineer, with a deep mechanical knowledge.
Diesel lovers will enjoy his remarkable study on the Bosch VE Diesel injection pump. The original article appeared in 2005 on Forum Auto, and is published here with his kind permission.

 

The Bosch VE injection pump, by Bricofoy

Click on images to enlarge

 

"Here was my occupation on last friday night : prepare a nice Bosch pump to install in a Peugeot 205.

 

cosses

 

The pump is in an undetermined state, so we're off for a reconditionning with a complete disassembly, change of seals and all.
And I did well, for it was filled with sludge.

Here is our starting point : a pump, suitable seal kit, control lever bushing and input shaft lip seal.

 

 

cosses

The same nearly one our later :

There's a lot of parts in a Bosch pump. There are still more in a Roto Diesel !

I didn't take pictures during dismantling, so just follow in reverse order if you have doubts about the disassembly ;-)

Needless to say, once the pump is in pieces, all the parts must be thoroughly cleaned. Further, liberally lubricating the rubbing, sliding or reciprocating parts with penetrating oil is an obligation during reassembly.

 

 

High pressure delivery valves

 

delivery valves

 

For starters, we will begin by reassembling the pressure head delivery valves. Here are the different components : valve, spring, adjusting spacer, nice brand new seal, and fitting.

 

 

fitting

 

The parts are put together again :

 

fittings

 

Et hop :

 

 

Transfer pump

 

Now let's get to the real stuff :

pump casing

 

Hoooo, it's empty ! You can even see my jeans through the opening at the bottom :lol:

 

stator

 

We begin by installing the transfer pump stator :

 

openings

 

Make sure to correctly position the drilled holes in front of the threaded holes at the bottom of the pump housing (green circles).

 

rotor and vanes

 

Then the rotor and its vanes :

 

rotor

 

First the rotor :

 

transfer pump assembly

vanes

 

Then inserting the vanes with round (and long) nose pliers :

 

cover

 

 

Then the transfer pump cover plate :

 

cover

 

Now in place with its screws

 

 

 

Input shaft

 

shaft

 

We are now installing the input shaft :

 

elastic drive pads

elastic drive pads

 

Before putting it in its place, we must insert the governor drive gear and its two new elastic drive pads :

 

washer

 

 

Next the washer that goes behind :

 

key

 

Finally the transfer pump drive key :

 

inserting shaft

 

The whole assembly is now inserted into the pump housing :

 

shaft

shaft

 

Here goes, fully home :

 

 

Roller carrier ring and face cam ring

 

roller carrier

 

 

Now we are reassembling the following : the roller carrier ring, with its drive pin for the timing mechanism.

 

pin

 

Inserting the drive pin into the roller carrier (caution, place the pin hole in the right position !) :

 

roller carrier in pump housing

roller carrier installed

 

The assembly is then installed in the pump housing :

 

drive pin

 

 

Here is where the drive pin goes when in its working position :

 

timing cylinder

drive pin

 

It protrudes into the timing piston cylinder :

 

piston

 

OK, now we only have to slide it back into the roller carrier in order to install the timing piston :

 

trunnion

 

Reassembling the piston and trunnion :

 

piston

 

Next the piston is inserted into the cylinder :

 

communication port

 

Mind the correct orientation ! The hollow spring housing must face the transfer pump communication port (green) :

 

drive pin

 

Now sliding the drive pin back into position

 

pin

locking pin

 

and lock it in position with the locking pin

 

circlip

circlip

 

and secure it with the clip :

 

cover

seal

 

Now reinstalling the timing cover, with a new seal :

 

cold start device

cold start device

 

Next on the other side, the spring and electric cold start device :

 

cover

 

I finally got rid of the cold start mechanism, since the 205 normally has none, and so doesn't have any cold start control. I replaced it with the regular cover :

 

spider

spider

 

Installing the four arm spider that drives the rest of the pump mechanism :

 

installing rollers

Rollers and washers

 

Next to the rollers. They are shown here outside of the pump : please note the orientation of the washer, which is convex to match the curvature of the carrier :

 

Rollers in pump casing

Rollers in pump casing

 

spring

spring

 

Next the spring in the center :

 

cam disk

 

And the cam disk :

 

orientation of drive peg

 

When installing this part, the plunger drive peg (green circle) must line up with the input shaft key.

 

cam disk

When riding the rollers, the face cams move the plunger axially, compressing fuel for injection. Timing is modified by rotating the roller carrier by means of the timing piston located beneath.

Here I changed the cam disk, since the one which came with the pump doesn't have the same profile. The new one comes from a 205 injection pump.

 

 

Distributor plunger

 

plunger

 

Now the distributor plunger :

 

sleeve

 

We then add the control sleeve.

Under the control of the regulator levers, the sleeve slides and variably covers the plunger spill port (green circle on previous picture).

 

During injection, the plunger moves axially under the thrust of the cam disk. According the control sleeve position, the spill port is uncovered when the plungers slides, after a variable portion of the stroke. Thus the injected fuel is metered (when the spill port is uncovered, high pressure fuel escapes, and injection ceases).

The plunger is named "distributor" because it revolves and directs fuel to each delivery port, via its slits and channels.

 

High pressure head

 

distributor plunger

 

We now insert the distributor plunger into the high pressure head :

 

springs

springs

 

next the springs :

 

spacer

spacer

 

The spacer at the end of the plunger :

 

assembly

Assembly in pump housing

 

and we put everything back together into the pump :

 

 

Governor speed levers

 

speed levers

 

We will now reassemble the governor speed levers and springs :

 

springs

spring housing

 

The installation is tricky due to the spring position :

 

lever screws

 

Detail of the lever pivot with special screws (I made a purpose socket by grinding an old 13 mm socket)

 

seals

 

Installing screws with new aluminium seals :

 

try

 

We just have to insert the lever assembly from above :

 

slits and channels

 

Shucks, no way ! ... We have to remove the pressure head and insert the levers BEFOREHAND :mad:

By the way, please note on the plunger, the spill port (green), distributor slit (red), and the 4 metering slits at the end (green). The plunger is hollow to connect everything.

 

High pressure head and springs

 

The high pressure head with all the springs in place :

 

lever close up

levers in pump

 

We just have to reassemble the whole thing, then remove it once or twice because the springs won't fall in place, and voila :

 

 

Governor

 

Let's now see the governor.

Governor parts

 

Here are the parts :

 

fly weight assembly

Assembling fly weights

 

Assembling the fly weights :

 

fly weight in governor

 

Replacing the fly weights into the governor :

 

sleeve

sleeve port

 

Then placing the governor sliding sleeve (please note the calibrated port for governing the injection timing according to engine load)

 

Inserting the governor shaft

 

Then installing the governor shaft into the pump housing :

 

washers

washers

 

Those wahers go behind the governor assembly :

 

governor

inserting the governor

 

Then the governor itself :

 

tightening the governor shaft

 

We now insert the shaft into the casing, and tighten it with an Allen wrench and an open wrench, to hold it in position while tightening the locknut.

The shaft position is key, as it commands the injection timing. Make sure its position is adequately marked when dismantling :

 

 

Governor cover

Voila, now the pump assembly is complete, we just have to reinstall the case cover, and the transfer pressure regulating valve. I could have installed the valve before, but...

 

old bushing

driving out the old bushinge

 

We first drive out the old control lever bushing :

 

new bushing

 

Then we replace it with a brand new bushing :

 

bushing installed

driving in the bushing

 

Carefully driving it home with a a bolt and large washers :

 

springs

 

Next installing the command shaft and speed control springs :

 

speed control springs

 

Close up of the hooking up of the speed control springs onto the governor levers : the flat (green) is inserted into the lever notch (red) then pulled back home :

 

control lever

control lever

Et hop, we just have to replace the cover (with a new seal) and secure it.

We now reinstall the accelerator lever, taking care to put it back in its original position with regard to the markings on the shaft and lever (of course make sure you carefully mark the correct position during disassembly).

 

valve

valve

 

Now reinstalling the transfer pressure regulating valve (of course with new seals) :

 

shut-off valve

shut-off valve

 

Next the solenoid actuated fuel shut-off valve :

 

lip seal

lip seal

 

Finally the input shaft lip seal (it is installed with a large socket and driven home by screwing the pulley nut onto the shaft).
Sorry, no photo.

 

 

 

pump reassembled

 

And voila, we're done. All we have to do is bolt it into the Peugeot 205 ! :-)"

With kind permission of Bricofoy

 

 

Image courriel  Send an email to Bricofoy

 

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© 2005-2018 Gilles Thesee
Last modified
29-12-2013 @ 00:31:52

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