Bosch VE Diesel Technical Instruction Manual

[sclarke]

Blokes, Lasses, Cattle dogs and Strays.

Been on the prowl to find out some info on how the Bosch Injection System works and after many hours of Trawling i found this on a Dodge website

Land Rover 200 and 300 engines use the Bosch VE Distributor Pump injection system. Finding info on these pumps and how the whole injection system works is a hard task, but ive done it.

Once again Clarkie has come to the rescue and given you all an excuse to read a manual and become a betterer smarterer person, i feel gooderer for this exersise.

The link for the PDF is here, its about 1.7mb, so ok for you country folk with Dial up.

http://members.dodo.net.au/~sclarke7171/files/bosch_ve_pumps.pdf

Now if you read it and cant understand any of it and are scared by all the German lingo to do with add on modules and reversal timing exploitation. Then i suggest you dont tinker with your belovered TDI engine......
I only got it to further understand the black art of Bosch Diesel injection.

Enjoy and remember, Clarkie is the LORD....... Bow to him and he shall supply all that is good.
I might run for Government this year, damn i could improve this world.....

[Pedro_The_Swift]

how? zebra striped school uniforms perhaps?:angel:

[sclarke]

how? zebra striped school uniforms perhaps?:angel:

No better, All Government cars will be painted like a Porcupine, then you will know when the *****s are around.....

[B92 8NW]

Nice work, I reckon you had to hack Bosch's servers to get it though!

[rick130]

and Ian/Leo109's pump tweaking tutorial gives a pretty good overview of how each adjustment works ;)
http://www.aulro.com/afvb/attachment.php?attachmentid=326&d=1152411367

[sclarke]

Nice work, I reckon you had to hack Bosch's servers to get it though!

Nope, just trawled thru all the google searches until i found it on a yahoo group.

http://autos.groups.yahoo.com/group/cummins4BT/

They have some stuff on Landy conversions also.

Its in the File section also

[sclarke]

and Ian/Leo109's pump tweaking tutorial gives a pretty good overview of how each adjustment works ;)
http://www.aulro.com/afvb/attachment.php?attachmentid=326&d=1152411367


Very good article, but i wanted to know more about the whole system.
Guess thats why the Volvo freaks come to me about Bosch D-Jet and K-Jet, over 10 years in building some sleeper Volvo's.......

[rick130]

thats why the Volvo freaks come to me

almost mud pit material there :lol2:

and thanks mate, will be downloading the file too.

[turbo_diesel_robbo]

Hi all, I'm about to replace a 300tdi injector pump on my old disco so i've been looking up online material and came across this...

Bosch diesel injection pump rebuild (http://etc.gnarlodious.com/Vanagon/Bosch_Pump/-Rebuild.html)

(this is from a VW site but the injector pump seems to be very similar)

has a link to the Bosch_VE_Pumps.pdf in there too (same doc linked too elsewhere in this thread), fascinating read if you're into that kind of stuff. The humble mechanical injector pump is a amazing piece of engineering...

I plan to repair the old injector pump once i've done the swap out. Its got a pretty heavy leak from the accelerator input shaft which is hopefully a pretty straight forward fix.

Photo link below...

IMG_1470a on Flickr - Photo Sharing! (http://www.flickr.com/photos/8020259@N04/3858026169/)

I've been trying to source a rebuild kit online, can anybody help? The only ones I can find are rebuild kits from VW sites, does anyone know if the Bosch VE pumps on VW's have common seals and bushes with the Land Rover ones?

Cheers, turbo_diesel_robbo

P.S. Upside of the diesel leak is that my engine bay is the cleanest its ever been!

[Disco_owner]

That's a bit of leaking you've got there ...:D

If you contact British motor imports in morning they may be able to help you with a rebuild kit.

British Motor Imports Pty Ltd

(02) 4587 7807Send this listing to your mobile (http://www.whitepages.com.au/wp/mobile/send-to-mobile-accessible?entryId=213970782&lineSequenceNumber=1&searchType=B&channel=WP)
Mulgrave
32 Groves Ave
Mulgrave NSW 2756
http://www.whitepages.com.au/wp/images/spacer.gifShow map... (http://www.whitepages.com.au/wp/whereIs.do?locality=Mulgrave&streetNumber=32&streetName=Groves&streetType=Ave&state=NSW&product=N17W%23213970782%23British+Motor+Imports+P ty+Ltd&channel=WP)


www.bmiparts.com.au (http://www.bmiparts.com.au)

good luck with it.

[PAT303]

After just spending a week trying to get the pump timing right I'll be leaving mine alone.The difference between the engine sounding like it has a sump full of marbles and running sweet is only .02 of a mil.It is good fun finding out how they work but mines never being fiddled with again. Pat

[turbo_diesel_robbo]

well, my new pump arrived. a bosch r509-2 (the old one was a r509, I don't know the difference, hopefully the r509-2 leaks less!) which cost me 302 pounds plus another 75 for air freight (off ebay). so it was about $750 in the country. not bad for a brand new pump, I reckon.

https://www.aulro.com/afvb/images/imported/2009/09/1448.jpg

installed...

https://www.aulro.com/afvb/images/imported/2009/09/1449.jpg

https://www.aulro.com/afvb/images/imported/2009/09/1450.jpg

fitted a new timing belt, new oil and fuel filter at the same time, took all day, but i'm pretty particular (slow). I was worried that the new pump was dry and that i'd have a hard time starting the motor, or do damage due to no lube, but the pump was full of some yellow fluid which I though I might need to purge first, but when it was all done I turned it over two times with the injector pipes cracked until I got a dribble, then tightened them up and she fired right up! turns out that yellow fluid is probably some type of diesel. All I needed to do was adjust the idle stop and away we went.

no puddles of diesel under my car anymore. happy days.

P.S. an hours drive later the circlip came off my thermo fan, driving the fan into the radiator requiring a visit to thompsons radiators in moorabbin who did a rush repair for me for $77. thanks guys.

P.P.S discovered that ULR land rover in port melbourne sell diesel filters for $38 (repco tried to sell me one with the water drain valve missing for $115)

[Disco_owner]

Rob;
where did you source your new pump from ? and is the verdict?

[turbo_diesel_robbo]

I got the injector pump off ebay.co.uk from a 'private seller' I can try and get in contact with him if you like. The pump has identical markings to my original one except that as previously mentioned its a R509-2 rather than a R509, and the serial number is a bit different, but mostly it missing the Land Rover part number, so I guess this bloke get them outside of the Land Rover supply chain. It came with no paper work, the pump had factory looking shipping plugs except no plugs on the outlets to the injector pipes which I though odd.

The verdict is that if I hadn't done the job myself I wouldn't notice the difference. The performance seems identical (not very spritely), the motor sounds identical (angry), it starts the same (very easily) (maybe a little less smoke on start, but cant be certain). I'm a little dissapointed because I thought a pump that is at least 300,000km newer might perform a bit better.

Which lead me to a question for you all... TUNING. Should I get this engine tuned? I asked a local private land rover mechanic and he was adament that I should get it tuned, but as I said I can't tell the difference from the last pump. So it begs the question, did my old pump and the new one both need a tune, or is this bloke trying to get a few hundred bucks out of me because he didn't get to stitch me up for a new injector pump himself?