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(/qs3/pubsys2/xml/en/manual/4021539/4021539-titlepage.html)

Preparatory Steps
 WARNING 
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the
negative (-) battery cable last.

• Disconnect the batteries. Refer to the OEM service

manual.

 WARNING 
The pressure of the fuel in the line is sufficient to
penetrate the skin and cause serious personal
injury. Wear gloves and protective clothing.

• Clean the debris from around the in-line fuel

injection pump.
• Remove the open-drive coupling cover.

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Remove
 WARNING 
Wear appropriate eye and face protection when
using compressed air. Flying debris and dirt can
cause personal injury.

 WARNING 
When using solvents, acids, or alkaline materials
for cleaning, follow the manufacturer's
recommendations for use. Wear goggles and
protective clothing to reduce the possibility of
personal injury.

 CAUTION 
Use a cleaning solvent that will not harm aluminum.

Use a brush and solvent to clean the fuel injection pump.

 CAUTION 
Both the right and left-bank fuel pumps must be
removed/installed with the engine in this position.
Severe engine damage can occur if static injection
timing is not set properly.

Rotate the engine slowly clockwise until the crankshaft

damper pointer aligns with the specified engine timing,
which is provided on the engine dataplate, before Top
Dead Center for the right - bank number 1 cylinder on
the compression stroke.

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Remove the right - bank number 1 rocker cover. Verify

the number 1 cylinder is on the compression stroke and
at specified timing before Top Dead Center.
Note : Both the rocker levers will be loose, or the
push rods will be the same height, if the piston is
on the compression stroke.

Remove the fuel injection pump timing pin cap (2). Verify
the position of the timing pin. The fuel pump must be
locked. Reverse the position of the timing pin (1) to lock
the pump, as shown.

Install the timing pin, cap, and sealing washer.

Torque Value: 30 n•m [ 22 ft-lb ]

Note : If the pump is to be reused, the timing pin
must set in the locked position to preserve the
pump timing.

 WARNING 
Some state and federal agencies have determined
that used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with
local environmental regulations.

Disconnect the electrical connections. (1)

Disconnect the low and high-pressure fuel lines (2).

Refer to Procedure 006-024 in Section 6.
(/qs3/pubsys2/xml/en/procedures/57/57-006-024-tr.html)

Remove the oil line. (3)

Install a protective cover to prevent any dirt or dust from

getting into the discharge port of the injection pump or
inlet port of the nozzle connector.

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Remove the overflow/pressure regulator valve from the

mechanical fuel pump. Identification, removal,
inspection, clean for reuse, and assembly of the
overflow/pressure valve is found in the following
procedure.

Refer to Procedure 005-066 in Section 5.

(/qs3/pubsys2/xml/en/procedures/57/57-005-066.html)

Remove the overflow/pressure regulator valve from the

electronic fuel pump. Identification, removal, inspection,
clean for reuse, and assembly of the overflow/pressure
valve is found in the following procedure.

Refer to Procedure 005-066 in Section 5.

(/qs3/pubsys2/xml/en/procedures/57/57-005-066.html)

If equipped, remove the four capscrews securing the fuel

pump drive gear cover plate. Remove the fuel pump
drive gear cover plate and the cover plate o-ring.

Remove the fuel injection pump timing pin cap (2).

Reverse the position of the timing pin (1) to unlock the
pump and install the pin, cap and sealing washer.

Torque Value: 30 n•m [ 22 ft-lb ]

 CAUTION 
Severe damage to the fuel pump may occur unless
the fuel pump is unlocked prior to breaking free the
drive gear assembly from the drive shaft.

Break loose the large nut (1) and washer securing the

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drive gear assembly to the drive shaft.

Note : For a two piece gear assembly: Remove

the two capscrews (2) securing the drive gear to
the hub, as shown.

One-piece gear assembly

Thread and Hand tighten the remover screws (3) from

the short threaded side on the drive gear and hub
assembly (4).

Slide the mounting plate (1) on the remover screws (3).

Until it contacts the flat on the remover screws.

Thread and hand tighten the nuts (2) to make the

mounting plate (1) seat against the flat on the remove
screws.

 CAUTION 
Both the right and left-bank fuel pumps must be
removed/installed with the engine in this position.
Severe engine damage can occur if static injection
timing is not set properly.

Rotate the engine slowly clockwise until the crankshaft

damper pointer aligns with the specified engine timing,
which is provided on the engine dataplate, before top
dead center for the right-bank number 1 cylinder on the
compression stroke.

Remove the right-bank number 1 cylinder rocker cover.

Verify the number 1 cylinder is on the compression
stroke at specified timing before Top Dead Center.
Note : Both rocker levers will be loose or the push
rods will be the same height if the piston is on the
compression stroke.

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Verify the engine is in the correct position for fuel pumps

to be removed from the engine.

Remove the fuel injection pump timing pin cap (2). Verify
the position of the timing pin. The fuel pump must be
locked. Reverse the position of the timing pin (1) to lock
the pump, as shown.

Install the timing pin, cap, and sealing washer.

Torque Value: 30 n•m [ 22 ft-lb ]

Note : If the pump is to be reused, the timing pin

must set in the locked position to preserve the
pump timing.

Remove the injection pump assembly:

Open-Drive (Base-Mount) Fuel Pump (P8500)

• Disconnect the coupling bolts (1); only loosen the
larger bolt (5).
• Fabricate a spreader bolt and use it to loosen the
pinch plate (6).
• Loosen the four injection pump bracket mounting
bolts (2).
• Remove the injection pump and bracket (3) at an
angle as one unit.
• Remove the mounting bolts (4).

Note : The removal of the drive coupling from the

injection pump is the responsibility of Bosch.
Contact a Bosch™ dealer for instructions before
delivering the pump to the repair facility.

Flange-Mount Fuel Pump (P8500, P7100, and

RP39)
• Remove the four capscrews(1), washers, and nuts
holding the pump to the drive housing.
• Remove the injection pump bracket mounting bolts
(2).

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Note : The right-bank fuel pump bracket has six

mounting bolts. The left-bank pump bracket has
three mounting bolts.

To remove the pump, slide the pump to the rear and

disengage the spline coupling (2) from the drive housing
(3) and the pump driveshaft spline adapter (1) from the
spline coupling (2).

Remove the pump from the drive housing.

Remove the mounting bolts and the fuel pump bracket.

The pump driveshaft spline adapter MUST be removed

and kept if the existing pump needs to be replaced or
repaired. Replacement fuel injection pumps do NOT
include spline adapters.

See instructions below for removal of the driveshaft

spline adapter.

 CAUTION 
Check to make sure the injection pump timing lock
pin is removed before continuing. Severe damage
to the fuel injection pump will occur unless the fuel
injection pump is unlocked.

Remove the fuel injection pump timing pin cap (2).

Reverse the position of the timing pin (1) to unlock the
pump and install the pin, cap and sealing washer.

Torque Value: 30 n•m [ 22 ft-lb ]

To remove the nut securing the spline adapter to the

driveshaft, hold the spline adapter with service tool, Part
Number 3163313, or equivalent.

Use a 41mm socket and long-handled ratchet or breaker

bar to loosen the nut.

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Remove the nut from the driveshaft.

To remove the driveshaft spline adapter from the

tapered shaft of the fuel pump, use a standard two-jaw
puller.

Remove the spline adapter and Woodruff key.

Note : For an Open-Drive (Base-Mount) fuel

pump, a woodruff key is only used on the rear of
the shaft. When assembling the spline adapter to
the pump, the woodruff key is not needed.
Note : The spline adapter must be removed and
kept if the existing pump needs to be replaced or
repaired. Replacement fuel injection pumps do
not include spline adapters. Only an authorized
Bosch™ repair location may service this fuel
pump.

Clean and Inspect for Reuse

 WARNING 
Wear appropriate eye and face protection when
using compressed air. Flying debris and dirt can
cause personal injury.

 CAUTION 

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Use a cleaning solution that won't hurt aluminum.

Use a brush and solvent around the areas where

connections where the fuel pump were removed to make
sure no dirt remains on the fuel injection pump.

Dry with compressed air.

Inspect the fuel injection pump for the following damage:

• Mounting surfaces and capscrew holes for cracks

and raised metal
• Damage to threads
• Damaged cable or harness connectors.

Inspect the fuel pump shaft and threads for damage.

Inspect the spline adapter for damage or missing

splines.

Inspect the nut threads and flats for damage.

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Install
Remove the fuel injection pump timing pin cap (2). Verify
the position of the timing pin. The fuel pump must be
locked. Reverse the position of the timing pin (1) to lock
the pump as shown.

Torque Value: 30 n•m [ 22 ft-lb ]

Seal Replacement

A. O-ring seal (flange drive housing)

B. O-ring seal (flange drive oil supply)
C. Lift pump gasket
D. O-ring seals - EHAB to injection pump
E. Sealing washer (banjo connectors).

 CAUTION 
Failure to prelubricate the fuel injection pump can
cause pump damage.

Prelubricate the fuel pump oil sump by adding clean

engine oil to the fuel pump oil drain opening until oil
comes out of the drain.

 CAUTION 
Check to make sure the injection pump timing lock
pin is removed before continuing. Severe damage
to the fuel injection pump will occur unless the fuel
injection pump is unlocked.

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Prior to installation , the tapered fuel pump shaft and

spline adaptor should be cleaned with non-petroleum
based cleaner, (3824510) or equivalent, and wiped with
a lint free rag. Contact with tapered shaft and inside of
the spline adapter with bare hands should be avoided as
it contaminates the mating surfaces.
Note : For an Open-Drive (Base-Mount) fuel
pump, a Woodruff key is not required for
installation of the spline adapter.
Slide the adapter onto the fuel pump shaft.

Install the nut and hand-tighten. Hold the spline adapter

with service tool, Part Number 3163313 (with breaker
bar attached), or equivalent, and tighten the nut, use a
41-mm socket.

Pump
Torque
Model 339 N•m 250 ft-lb
Value
P8500
Pump
Torque
Model 339 N•m 250 ft-lb
Value
P7100
Pump
Torque
Model 475 N•m 350 ft-lb
Value
RP39

 CAUTION 
Both the right- and left-bank fuel pumps must be
removed/installed with the engine in this position.
Severe engine damage can occur if static injection
timing is not set properly.

 CAUTION 
Check that all packing caps are removed before
installation.

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 CAUTION 
The pump needs to locked at this point.

Rotate the engine slowly clockwise until the crankshaft

damper pointer aligns with the specified engine timing,
which is provided on the engine data plate, before Top
Dead Center for the right-bank number 1 cylinder on the
compression stroke.

Remove the right-bank number 1 cylinder rocker cover,

and verify the number 1 cylinder is on the compression
stroke.
Note : Both of the rocker levers will be loose or
the push rods will be the same height if the piston
is on the compression stroke.

Verify the engine is in the correct position for fuel pumps

to be installed on the engine.

Remove the fuel injection pump timing pin cap (2). Verify
the position of the timing pin. The fuel pump must be
locked. Reverse the position of the timing pin (1) to lock
the pump, as shown.

Install the timing pin, cap, and sealing washer.

Torque Value: 30 n•m [ 22 ft-lb ]

Install the retaining rings inside the spline coupling.

Install the spline coupling (1) onto the pump driveshaft

gear.

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Install the mounting bracket to the fuel pump. Make sure

the dowel rings in the bracket align with the fuel pump.

Note : Different fuel pumps and mounting

brackets are used between generator-drive and
industrial engines.

Open-Drive (Base-Mount) Fuel Pump

Tighten the four pump bracket mounting capscrews (4).

Set the fuel pump assembly in position.

With the bracket installed on the pump, set the fuel

pump assembly at an angle, and install the assembly (3)
on the engine. Make sure the dowel rings in the bracket
align with the holes in the block.

Tighten the bracket capscrews (2). Tighten the coupling

capscrew (1).
Note : For a Flange-Mount Fuel Pump do not
tighten the capscrews.
Bracket-
Mounting Torque
65 N•m 48 ft-lb
Capscrews Value
(2)
Coupling
Torque
Capscrews 108 N•m 80 ft-lb
Value
(1)
Pump-
Mounting Torque
65 N•m 48 ft-lb
Capscrews Value
(4)
Pinch Bolt Torque
163 N•m 120 ft-lb
(5) Value

Note : Loctite™, Part Number 3824040 or

equivalent, can be required to keep the shaft from
slipping on the coupling. After installation, add a
couple of drops to the pinch bolt slot.

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 CAUTION 
If the pump does not align, do not force the pump
and drive into alignment. Forcing will result in fuel
pump damage. Use vegetable oil to lubricate the
inside of the injection drive housing.

Flange-Mount Fuel Pump (P8500, P7100, and RP39)

Engage the spline coupling, and install the pump

driveshaft gear into the drive housing. Install the flange-
mounting capscrews and nuts (1) and the fuel-pump-
mounting capscrews and washers (2).

Tighten the flange mounting capscrews (1).

Torque Value: 65 n•m [ 48 ft-lb ]

Tighten the fuel pump mounting capscrews (2).

Torque Value: 65 n•m [ 48 ft-lb ]

Note : The right-bank fuel pump bracket has six

mounting bolts. The left-bank pump bracket has
three mounting bolts. The flange-mount drive
housing uses support brackets located off the
number 2 camshaft follower covers for P8500 and
P7100 fuel pumps. The Flange-Mount drive
housing uses the ECM mounting bracket for RP39
fuel pumps.

 CAUTION 
Severe damage to the fuel pump will occur unless
the fuel pump is unlocked prior to operation.

Remove the fuel injection pump timing pin cap (2).

Reverse the position of the timing pin (1) to unlock the
pump and install the pin, cap, and sealing washer.

Set with the intial torque value.

Torque Value: 30 n•m [ 22 ft-lb ]

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Note : The final torque value should only be set if

the pump is verified to still be in the correct timing
position after the initial torque value is set.
Note : The timing pin is reversed when installing
the on the engine.
Set the final torque value.

Torque Value: 30 n•m [ 22 ft-lb ]

 CAUTION 
Use an evaporating cleaning solvent to clean the
driveshaft tapered nose. Any lubricant present can
allow timing to slip.

 CAUTION 
The timing pin must be removed before tightening
the large nut (1) above 12 N•m [106 in-lb], or fuel
pump damage will occur.

Install the drive gear and hub assembly on the shaft.

Install the large nut (1) and washer securing the drive
gear assembly to the drive shaft. Intail seating torque
values for one-piece and tw0-piece assemblies:

Torque Value: 12 n•m [ 106 in-lb ]

Verify the engine is still in time after seating the large nut
(1).

Note : Check to make sure the drive gear

assembly will be supported by the gear train. If
not, use a wire to prevent it from dropping into the
oil pan.
Note : A key is not installed on flange-mount fuel
pump drive assemblies.
There are one-piece and two-piece drive gear
assemblies. Tighten the nut (1) to the final torque value
to secure the drive gear assembly to the driveshaft.

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One-Piece Torque
366 N•m 270 ft-lb
Assembly Value
Two-Piece Torque
434 N•m 320 ft-lb
Assembly Value
Tighten the four capscrews (2) securing the drive gear to
the hub on two-piece assemblies only.

Torque Value: 108 n•m [ 80 ft-lb ]

Install the gear cover (if removed). Refer to Procedure
001-031 in Section 1.
(/qs3/pubsys2/xml/en/procedures/57/57-001-031.html)
Note : One-piece drive gear assemblies have two
capscrews, while the two-piece drive gear
assemblies have four capscrews.

If equipped with a fuel pump drive gear cover plate,

install the fuel pump drive gear cover plate o-ring.

Lubricate the o-ring with vegetable oil.

Tighten the capscrews.

Torque Value: 41 n•m [ 30 ft-lb ]

 WARNING 
Some state and federal agencies have determined
that used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with
local environmental regulations.

Install all the fuel pump oil lines (3).

Torque Value: 24 n•m [ 212 in-lb ]

Install the high-pressure fuel lines (2). Refer to
Procedure 006-024 in Section 6.
(/qs3/pubsys2/xml/en/procedures/57/57-006-024-tr.html)

Torque Value: 23 n•m [ 204 in-lb ]

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Install the low-pressure fuel lines (2). Refer to Procedure

006-024 in Section 6.
(/qs3/pubsys2/xml/en/procedures/57/57-006-024-tr.html)

Torque Value: 27 n•m [ 239 in-lb ]

Install the electrical connection (1).

 WARNING 
The pressure of the fuel in the line is sufficient to
penetrate the skin and cause serious personal
injury. Wear gloves and protective clothing.

Install the overflow/pressure regulator valve onto the

mechanical fuel pump. Refer to Procedure 005-066 in
Section 5. (/qs3/pubsys2/xml/en/procedures/57/57-005-
066.html)

Install the overflow/pressure regulator valve onto the

electronic fuel pump. Refer to Procedure 005-066 in
Section 5. (/qs3/pubsys2/xml/en/procedures/57/57-005-
066.html)

Install the open drive coupling cover.

Install the cover bracket and capscrews.

Torque Value: 60 n•m [ 44 ft-lb ]

Finishing Steps

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 WARNING 
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the
negative (-) battery cable last.

• Install the electrical connection.

• Connect the batteries. Refer to the OEM service
manual.
• Start the engine and check for leaks.

Last Modified: 18-Jul-2012

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