Bypass valve for bosch Kamaz injection pump

Symptoms of malfunction of fuel injection pump KAMAZ 740, fuel injection pump KAMAZ 4310

Malfunctions of fuel pumps and regulators manifest themselves in a violation of adjustment due to wear of parts, which results in the occurrence of extraneous noise, overheating and fuel leakage.

The main reason for the malfunction of the fuel pump is wear of its parts, weakening of the tightness in the fits, increased gaps in the moving joints, violation of the location of the parts, and deposits on the surface of the parts in the form of dirt and carbon deposits.

The consequence of pump malfunctions can be a decrease in the supply of fuel in the required quantity and uneven supply. Failure to properly supply fuel is usually caused by wear of plunger pairs, pump discharge valves, plunger drivers, rack clamps, rack teeth and bushing gears, and clogging of injectors. Such malfunctions lead to a decrease in engine power and efficiency.

Uneven supply of fuel to the engine cylinders will lead not only to unstable operation at low speeds, but also to interruptions in the operation of individual cylinders, which will be accompanied by vibration of the engine block.

Fuel injection pump malfunctions include uneven start of injection and delay in injection timing of a multi-section pump, which occurs due to wear of the pusher adjusting bolt, roller axis, pusher and roller housing, ball bearings, as well as wear of the cam shaft.

Wear of plunger pairs and injection valves significantly affects the change in the fuel injection advance angle.

The KAMAZ engine does not start or starts poorly;
Uneven operation of the KAMAZ engine;
During operation, noises and knocks from the KAMAZ engine occur.

Basic rules for installing injection

There are several rules for setting injection timing that should be followed.

It is preferable to start manipulations at the operating temperature of the motor. However, if the symptoms are obvious, then you can start working in cold weather.
We install the drive so that the mark is on top, then lower the two bolts by 17 degrees.
If the injection is early, then move the pump drive in the direction of travel or clockwise.
If the injection is late, then vice versa.
You need to move the drive a little at a time and constantly tighten the bolts.

After all the manipulations, we start the KamAZ engine, such as art. 337 1111005 20. It is important that when it is activated during a sharp throttle, a ringing sound is heard. In this case, we move the drive back a little. The ringing will disappear, and the moment will be established.

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Replace the air filter;
Adjust the fuel supply angle;
Clean the injectors, adjust the injectors;
Repair the injection pump;
Check the operation of the KAMAZ injection pump.

Uneven operation of the KAMAZ 740, KAMAZ 4310 can be caused by loss of functionality of individual injectors, a malfunction of the high-pressure fuel pump or its regulator. Damaged injectors must be replaced, and the injection pump, as a more expensive part, is checked on a fuel stand and repaired if necessary.

Childhood diseases. Bosch injection pump for Kamaz Euro-2

It's time to touch on the topic of trucks, namely, the familiar Kamaz vehicle. Over the many years of production, it has undergone a huge number of changes and modifications, and to be honest, I can’t even say that it has become better as a result. It became a little, but again, they decided to adapt its already capricious engine to the Euro-2 environmental standard. And then they immediately began to hate this modification; both drivers and repairmen, having learned that it was Euro-2, immediately refused to undertake repairs.

Why is that? The problem is in the high pressure fuel pump. Due to the settings for Euro-2 standards, the unit is entrusted with the task of accurately dosing fuel at the required period. The engine itself is very smoky, especially when starting, the car smokes like a steam locomotive until it warms up. And to prevent this from happening, the pump supplies a very lean mixture. And it turns out that the car has a very small temperature range at which it starts without problems. From practical experience I would say -5 to +5. Yes, this is exactly such a feature of the pump. The lean mixture is simply not enough to start the engine, and you have to turn it more with the starter, and at the same time keep the gas pedal pressed to the floor. Over time, the plungers wear out, become loose, and starting problems begin almost constantly. The engine can start with half a turn when it’s cold, but when it’s hot it won’t start at all, or vice versa.

As we already know, on this modification of Kamaz vehicles, fuel injection pumps are found from two manufacturers - the domestic YAZDA series and the German-made Bosch. Those who don’t know will immediately exclaim: “Bosch would be the best, this is a domestic fuel injection pump that is problematic,” etc., because we are all accustomed to the fact that the Germans always associate this with the word “quality.” But no! In our case, it is the Bosch fuel injection pump that is the culprit of all the problems with the operation of the Kamaz engine. Let's figure out why.

The Bosch injection pump is a unit with an in-line arrangement of plungers and a Common Rail system. According to the developers, it is much more reliable, doses the mixture more accurately and is therefore economical. But the Germans apparently forgot to point out that the pump is very sensitive to the quality of fuel and oil. But we know very well what quality our diesel fuel is. Our “high-quality” fuel, not immediately of course, but kills all filter elements and the driver basically simply does not understand what exactly the problem is. And as a result, repairs require a large sum of money, since imported parts are very expensive.

If we talk about the domestic fuel injection pump, then this is a familiar V-shaped pump, the only difference from the previous ones is the adjustment to Euro-2 standards. Its advantage is that it is able to swallow diesel fuel, so to speak, of any quality and at the same time last longer than the imported version of the injection pump.

And so drivers, faced with all the delights of a German pump, buy a domestic one and simply change it. But this does not always work out, since not all engines have mounts for both pumps. It happens that when the engine is equipped with a Bosch fuel injection pump, it will not be possible to install a domestic one, so these fasteners have to be welded on. To avoid this, I recommend that before purchasing this car with a Euro-2 modification, you reconsider your priorities and it is best to purchase one with a domestic pump.

There is another problem associated with both injection pumps - the lubrication system. On such KamAZ vehicles, fuel injection pumps are included in the general lubrication system. And the Kamaz engine is very problematic, in terms of the fact that there are a lot of rubber bands, something is constantly leaking, it is not surprising that antifreeze gets into the lubrication system and two levels can be seen on the dipstick. And precisely for this reason, many vagaries with the start and operation of the engine are associated with oil getting into the fuel injection pump along with antifreeze.

My father had to work for some time on Kamaz with German fuel. In addition to the fact that it was difficult to start, the engine sputtered and stalled very often. When the engine once again stalled, we discovered that the rack that rotates the plunger does not move at all, that is, it turns out that all the plungers are jammed. Then, when the engine cools down, the rack moves again and the engine starts - miracles! At the same time, there were no two levels of oil on the dipstick, but it was watery to the touch, which is completely strange for oil. We decided to replace it immediately: we drained the oil, and while we were unscrewing the pan, droplets of antifreeze were visible at its bottom during removal. Everything immediately became clear. As it turned out, if antifreeze gets into the injection pump with oil, deposits remain on its plungers, which are very difficult to wash off, and when there are too many of them, at high engine temperatures, they simply jam.

In order for the Kamaz to be driven to a repair site in another city, it was necessary to temporarily fill the cooling system with water. The craftsmen completely overhauled the engine, replaced all the rubber bands and filled in new oil, and turned off the oil supply points to the injection pump so that no lubricant from the engine would enter the pump, but it would be lubricated by what was in it. The pump itself was disassembled, washed and now everything works as it should. I say this because it is better to immediately turn off the oil supply to the pump, even if there is no coolant in the engine lubricant yet. It won’t get any worse, but you will protect yourself and your wallet from problems and extra costs.

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fuel injection pump models and injectors for KAMAZ engines and their interchangeability

pump system KAMAZ engine , depending on the engine model, has the following model:

— engines KAMAZ 740.10 — injection pump YAZDA 33-02;
- engines KAMAZ 740.10-20 - fuel injection pump YAZDA 33-10; - engines KAMAZ 7403.10 - fuel injection pump YAZDA 334; — engines KAMAZ 740.11-240 — injection pump YAZDA 337-40; — engines KAMAZ 740.13-260 — injection pump YAZDA 337-42; — engines KAMAZ 740.30-260 — injection pump YAZDA 337-20; — engines KAMAZ 740.31-240 — injection pump YAZDA 337-20.05; — engines KAMAZ 740.50-360 — injection pump YAZDA 337-20.04 or injection pump BOSCH PE8P120A920/5RV (0 402 698 817); — engines KAMAZ 740.51-320 — injection pump YAZDA 337-20.03 or injection pump BOSCH PE8P120A920/5RV (0 402 698 817); — engines KAMAZ 740.60-360 — fuel injection pump YAZDA 337-23; — engines KAMAZ 740.61-240 — injection pump YAZDA 337-23.01; — engines KAMAZ 740.63-360 — injection pump BOSCH PE8P120A920/5RV (0 402 698 818). It is strictly forbidden to install injection pumps of other models. injector , depending on the engine model, has the following model:
- KAMAZ 740.10 engines - YAZDA 33-03 injector; — KAMAZ 740.10-20 engines — YAZDA 271-02 injector; — KAMAZ 7403.10 engines — YAZDA 271-02 injector; — KAMAZ 740.11-240 engines — YAZDA 273-31 injector; — KAMAZ 740.13-260 engines — YAZDA 273-21 injector (273-51 with BOSCH DLLA 148 SV3 142 323 nozzle); — KAMAZ 740.30-260 engines — YAZDA 273-21 injector (273-51 with BOSCH DLLA 148 SV3 142 323 nozzle); — KAMAZ 740.31-240 engines — YAZDA 273-21 injector (273-51 with BOSCH DLLA 148 SV3 142 323 nozzle); - KAMAZ 740.50-360 engines - YAZDA 273-20 injector (273-50 with BOSCH DLLA 148 S 1380 nozzle); — KAMAZ 740.51-320 engines — YAZDA 273-20 injector (273-50 with BOSCH DLLA 148 S 1380 nozzle); — KAMAZ 740.60-360 engines — AZPI 216, 216A injector (with DLLA 148P 1460 or AZPI 904 nozzle); — KAMAZ 740.61-240 engines — AZPI 216, 216A injector (with DLLA 148P 1460 or AZPI 904 nozzle); — KAMAZ 740.63-360 engines — AZPI 216, 216A injector (with DLLA 148P 1460 or AZPI 904 nozzle).

It is strictly forbidden to install injectors of other or different models.

From the forum

Question — Answer Question I have the following question for you. Kamaz 53215-15 Euro 2,740-31,240 I had a BOSCH injection pump before me. I already got it with fuel injection pump 337-42 (writes Euro). Consumption per hundred at 42 tons is 65 liters. I looked on the Internet and they write that the injection pump should be 337-20.5. Can someone please tell me what kind of fuel injection pump should be in place and approximately what the flow rate should be, as well as what kind of injectors it should be. Thanks to everyone in advance - The answer from the manual is that the analogue of BOS is indeed 337-20.05, but I personally know and technically support several cars with 337-42 - they work normally and consume fuel: the main thing is to adjust everything correctly. It’s just that the balance is between e-1 and e-2 in price: 40 versus 65, that’s the whole situation. The nozzles should be: 273-21 with sprays 273-20.

The question removed the forces and they are all black. The answer is nothing particularly terrible in this: the main thing is that they must also be dry. And ideally: smoking is allowed only on the nozzle of the atomizer. And then - only a shiny surface. E-1 273-30 nozzles on the E-2 internal combustion engine are always black (it looks like they are covered with soot), nothing works, but it’s much better when the nozzles indicated in post No. are installed. 542

Question Hello everyone! Is there such a question, has anyone come across this? Injection pump Bosch 320l injectors Azip 216 nozzles 905 pressure 260, changed the gaskets under the heads, ground the valves, changed the nozzles. It was not clear what pressure was on the old sprayers, at 210 they began to piss, if you pressed harder, it seemed like they were spraying, but the Kamaz started up perfectly on them and held xx, nothing floated, but it drove sluggishly, spinning poorly up to 2000 t/o on the go. Today I assembled everything, started it up, it seems that the ignition is early, and xx does not hold 300-400, what could this be connected with? Diesel is leaking from two high-pressure pipes. Could this be the reason? I tried tightening it, but it didn’t help.

Question guys, tell me, is it possible to convert 337-40 to 337-42? what do you need? what + and -? thanks Reply These 905 injector assemblies are crap. More or less BOSCH works. What pressure did you set? Answer 260 Everything seems to be correct, but the plates will tear periodically, and so on and so forth. It’s easier to install 273-20 injectors, it somehow works better.

The question is, is it possible to install injectors with the Bosch fuel injection pump 273-20? Answer Yes, we did it this way. Just check the motor model so as not to make a mistake. The same motor when equipped with Yaroslavl equipment can be looked at in the papers. They advised me and said it would be easier to set up. 740-51, I have 2 KamAZ trucks, one with a Yazda, 2 with a Bosch. Question It’s just bullshit. What is the difference? 273-20 indicated. So I wanted to ask you, dear expert. what is the difference? settings? rpm? etc. Answer Difference in settings, for example. Each brand of fuel injection pump is for its own engine. Answer The difference is very simple - 337-40 pump E-1 for a 240 hp engine. (with an injection advance clutch), 337-42 pump E-1 for a 260 horsepower engine (without a clutch). You can convert one into another only by increasing the feed rate by 337-40 to 337-42 (for all modes). But this is tantamount to trying to tame a wolf and make a dog out of it - they seem similar, but still not the same. 337-42 is better than 40 only because there is no clutch, especially since it is weak on this pump, and in general it is already an anachronism. But it will not be possible to remove the coupling and install the drive 42 of the pump, the shafts are different in diameter. Yes, and when installing a 42 pump, you need to put the drive gear on the “e” mark, or if it is not there, then move it by 12 teeth. I changed my 40 pump to a 42 and to be honest, day and night, the Kamaz is unrecognizable. It’s easier to do this here, especially since the price of any fuel injection pump (made by YAZDA) for disassembly is 5000 rubles. + 1000 rub. check with a diesel mechanic. Hence, the conclusion is that the 42 pump is better than the 40, but the best is the enemy of the good, especially if my memory serves me correctly, you have a 7403.10 engine, then for it the 40 pump is preferable and there is no need to change the drive. I have the same engine with a 40 pump on one KamAZ and it works great. Question, hello, kind people, tell me the Kamaz Euro2 engine 740.31.240 was Bosch Schaz Yazda 337.20.03, the first owner installed the engine dull, empty or loaded, it accelerates reluctantly. The question is, what should I do to get the Kamaz going? Can I take the fuel injection pump to check (it will be suitable for this engine) for another or look for a Bosch. There’s also oil in the collapse, I think that I read from you that you need to do a drain and where it can be done.

As far as I remember offhand, 337-20.03 is 360 hp, but it should roll decently on YOUR engine. And so: you need to increase the cyclic feeds in acceleration mode and full power. One of the bolts is outside and the other is under the top cover. The answer is to check the injectors, compression, injection and TCR pressure, as well as the pressure behind the FTOT - then everything will be clear. The question means, I’ll put aside my thoughts about Bosch for now, we’ll try ours, dear. By the way, with such a set of engine fuel pumps, tell me which high-pressure pipes to install, they suggest x. for 650 rubles per set they say the factory and there are 1400 rubles for these thick ones they say Moscow manufacturer.

Injection pump repair

Troubleshooting methods for a high-pressure fuel pump depend on the type of device, as well as the cause of the breakdown. We list the most common repair measures.

Replacing the plunger pair with your own hands

Before performing an independent check (without using a special stand), you must have handyman tools and a new plunger pair on hand, as well as have experience in performing repair work. We will describe the description of checking the condition of the high-pressure fuel pump using the example of a common Bosch injection pump.

It is necessary to understand that dismantling the pump depends on the specific model and even the car engine, so the procedure will be described in general terms. So, to replace a plunger pair (the most common type of repair) you need to:

remove the terminals from the car battery;
disconnect all wires and hoses suitable for it from the high-pressure pump;
dismantle parts that prevent its removal from the car;
unscrew the fasteners and dismantle the pump;
carefully disassemble the pump, it is important not to lose small parts, and also remember the disassembly sequence (you can photograph this process step by step on your phone);
unscrew and remove the plunger from the pump;
clean all pump parts from dirt (you can use special carb cleaners or similar cleaners for this);
check the rollers, bearings and racks on the pump; they should not show significant wear;
remove the valves and the so-called “silencer” from the old plunger pair, and then install them on the new pair;
Carry out installation work in reverse order.

Kamaz with Bosch equipment

Vehicle power system design

KAMAZ EURO injection pump device

The production of KAMAZ EURO-2 engines was banned in Russia in 2006, Europe even earlier - in 1999. This suggests that there are many interested in purchasing KAMAZ EURO-2 fuel injection pumps , even those that were produced earlier. The design of the KAMAZ EURO injection pump is a very interesting topic for KAMAZ vehicle owners, because no one like them knows that the power supply system and electrical equipment system are among those systems that cause the most trouble.

high pressure diesel injection pump KamAZ-740

The sale of KAMAZ fuel injection pumps has been very common lately, and there are quite a few buyers who want to buy KAMAZ fuel injection pumps . Companies such as SpetsMash, MigAvto and others are engaged in the sale of auto parts for KAMAZ vehicles.

Kama KAMAZ EURO-2 vehicles are designed in such a way that they require the installation of fuel injection pumps from various manufacturers. As a rule, Kama Euro-2 KamAZs are equipped with fuel injection pump 337.20 manufactured by Bosch and domestic. The fuel injection pumps differ slightly, namely in the accuracy of the fuel dosage. And yet, if you look at it, dosage accuracy is not the most important thing, because there are much fewer problems with domestic KAMAZ injection pumps. Even if you monitor the purchase of KAMAZ injection pumps from imported and domestic manufacturers, you can definitely say that drivers with imported injection pumps switch to domestic ones, and those drivers who have domestic KAMAZ injection pumps buy only domestic high-pressure fuel pumps. Probably, the domestic KAMAZ EURO injection pump design is a little simpler, and the simpler the design, the fewer problems.

If you decide to buy a KAMAZ injection pump, then it is best to contact an auto parts sales manager, who will be happy to tell you all the nuances of the issue. In addition, Internet technologies have been developing very recently, which make it possible to send a request for a KAMAZ injection pump device to the company’s email address.

Moreover, the transition from a Boshevsky to a Yaroslavl pump usually does not happen due to the poor quality of the injection pump itself. The thing is that the KamAZ Euro 2 injection pump drive, manufactured by the Germans, does not withstand our operating conditions - torn out plates have become almost a mandatory attribute of an imported unit. There have been cases when the pump drive on the same car was changed 5 times within one year. Please note that work on installing the KAMAZ EURO injection pump must be carried out by specialists at a specialized enterprise. The whole problem lies in compliance with the technology, which requires appropriate equipment.

Please note that promising to “normally” install and adjust the KAMAZ injection pump is not yet done, and it is not a fact that after installing the KAMAZ injection pump at a non-specialized service station, you will not have an inflated fuel consumption. Therefore, in order not to waste your nerves and get a good result, when replacing, repairing and adjusting the KAMAZ injection pump, contact a specialized service station.

on how to choose a KAMAZ EURO fuel injection pump , and of course compare the technical characteristics of the KAMAZ fuel injection pump, where you can easily select the required fuel injection pump according to the engine type.

DEVICE OF injection pump KAMAZ EURO 2

Injection pump device KAMAZ Euro 2 1. Low pressure fuel pump 2. Regulator top cover Regulator top cover 3 . Regulator weight holder 4. Regulator coupling 5. Rear regulator cover 6 . Levers with correctors 7. Starting spring lever 8. Drive regulator gear 9. Regulator intermediate gear 10. Boost corrector 12. Fuel pump housing 13. Fuel pump section 14. Cam shaft 15. Camshaft bearing cover 16. Plunger pusher 17. Bypass valve 18. Right rack 19. Left rack 20. Rack lever assembly 23. Pusher 24. Pusher roller 25. Pusher roller axis 27. Pusher spring 28. Fuel pump gasket 29 . Fuel pump drive eccentric 30. Regulator top cover gasket 31 . Regulator lever axis 32. Remote bushing 34. Regulator rear cover gasket 35 . Rack lever spring 36. Regulator spring 37. Spring lever 38. Drive gear block 39. Drive gear flange 40. Regulator rear cover plug 41 . Spring thrust ring 42. Pin tip 43 . Corrector gasket 49. Flange of the driven coupling half 50. Driven coupling half 51. Rear bearing cover 52. Gasket 53. Gasket 53. Gasket 54. Gasket 54. Gasket 55. Gasket 55. Gasket 56. Protective casing 58. Plug 60 . Pusher heel 69. Key 6x9 70 . Screw M8x20 71 . Screw M6x43 72. Screw М8х6g-19 73 . Screw M6x43 74 . Nut M20x1.5-6N 75. Washer 17 76. Flat washer 10x18 80. Bolt M6-6gx20 81. Screw M6-6gx32 83. Washer 16 84. Washer 17 85. Washer 7 86. Washer 21 88. Key 89. Lock washer 15 90 . Cork M10x1.25-6g 92. Plug of fitting 98. Spring washer 10 99 . Spring washer 102. Adjustable cotter pin 2x25 103. Low nut M14x1.5-6N 104. Bolt M6-6gx25 105. Lock washer 5x11x0.7 106. Conical spring washer 6x12 107. Nut M10x1.25-6N 108. Nut EM6-6N 110. Nut M8-6N

Adjustment and repair of KamAZ injection pump

KAMAZ trucks with a diesel engine have a large number of parts and assemblies of varying complexity. An important and complex component in the engine fuel supply system is the high-pressure fuel pump. Injection pumps operating in the KamAZ Euro 2 and Euro 3 power supply system are highly reliable, however, with a long service life and without timely maintenance, they may require repair.

To repair Kamaz fuel injection pump you need:

thorough diagnosis of the node;
special equipment is required (the DD-2115 device is used);
assessment of the condition of the plunger pairs of the fuel pump (the most common cause of failure of the fuel injection pump KamAZ 740, Euro 2, Euro 3).

Often, a superficial diagnosis is carried out to check for the presence of extraneous noise in the fuel injection pump. This approach cannot give an accurate conclusion, but only indicate a pump malfunction. To determine the exact malfunction, professional diagnostics in a specialized service is required.

Adjustment and repair of the KamAZ injection pump should be done if:

increasing vehicle fuel consumption;
no fuel supply from the pump to the injector;
jamming of the plunger pair in the pump;
difficulty starting the engine;
reducing diesel power;
the appearance of smoke and extraneous noise.

KamAZ trucks with Euro 2, Euro 3 and Euro 4 engine classes are available with fuel pumps from different manufacturers:

Fuel injection pump YAZDA 337.20 (337 42) - domestically produced, cheap, but inferior to Boshev's in terms of fuel dosage accuracy.
Bosch KamAZ injection pump Euro 2, Euro 3 and Euro 4 made in Germany. More accurate, but capricious.

The Bosch injection pump drive for KamAZ vehicles with a Euro class engine does not withstand Russian operating conditions, which leads to its rapid failure.

Therefore, it is important to carry out diagnosis in a timely manner. High precision is very important in this procedure. Regular diagnostics will prevent deviations in the Bosch system, which could lead to serious malfunction. Routine diagnostics are a completely affordable procedure that is much cheaper than repairing a fuel injection pump. Car service specialists will expertly answer any question you may have about the operation of the fuel pump.

Masters of the SAS No. 1 truck service center are ready to carry out work on the transition from Bosch fuel injection pump (Bosch) to YAZDA 337.20.

Advantages of contacting the SAS No. 1 car service:

professional service;
repair of Bosch fuel injection pumps (Bosch) and YAZDA, KamAZ with 740 engine at low prices in Moscow;
The car service center is equipped with specialized equipment for repairing fuel injection pumps;
Guaranteed quality repairs for your car.

You can contact us by phone +7 (985) 905-83-18 , and also sign up for a car service.