Fuel Injection Pump 0402746656 For Cummins 6BT 5.9L Engine

The part number 0402746656 refers to a Bosch VE (Verteiler-Einspritzpumpe / Distributor Injection Pump) commonly used in diesel engines. Here's a detailed breakdown:

Key Specifications & Features:

Type:

Rotary distributor-type fuel injection pump (Bosch VE series).

Mechanically controlled (no electronic sensors/ECU).

Applications:

Primarily used in Cummins 6BT 5.9L engines (mid-1980s to mid-1990s).

Found in Dodge Ram trucks (e.g., 1989–1993 Dodge D250/W250), industrial generators, marine engines, and agricultural machinery.

Critical Components:

Hydraulic Head: Distributes fuel to injectors.

Drive Shaft & Roller Ring: Drives the internal cam plate.

Advance Mechanism: Adjusts injection timing based on RPM.

Mechanical Governor: Regulates engine speed.

Fuel Cut-Off Solenoid: Stops fuel flow to shut down the engine.

 

 

Max Injection Pressure: ~850–1,200 bar.

Operating RPM Range: Typically 800–3,300 RPM.

Fuel Delivery: Calibrated for Cummins 5.9L's ~160–180 hp output.

Compatibility Notes:

Replaces older Bosch numbers like 0402746657 or 0402746655 (check service manuals for supersessions).

Verify engine serial number compatibility (e.g., Cummins engines with "B" or "C" series codes).

Parameter	Standard Value	Tolerance
Calibrated fuel delivery (full load)	62–65 mm³/stroke @1000 RPM	±2 mm³/stroke
Idle fuel delivery	8–12 mm³/stroke	±1 mm³/stroke
Cut-off RPM	≤3450 RPM	+50 RPM
Feed pressure	0.8–1.2 bar (inlet side)	-0.2 bar

 

Core Design Details

Distributor Rotor System

Axial-plunger distributor rotor (Ø≈12mm) driven by an internal cam plate, completing 6 injections per revolution (for 6 cylinders).

Plunger pre-stroke: Factory-set to 2.35±0.05mm (requires dial indicator measurement). Directly affects injection timing.

Mechanical Governor Structure

Dual-spring centrifugal governor:

Primary spring controls idle (800–1000 RPM); secondary spring manages full-load speed limit (≈3300 RPM).

Governor sliding sleeve wear causes RPM fluctuation (>±50 RPM indicates failure).

Torque cam: Provides extra fuel compensation at 1400–1800 RPM for mid-range torque boost.

Injection Advance Mechanism

Hydraulic auto-advance unit (fuel pressure-driven):

Idle advance: 6°–8° BTDC

Max advance at full speed: 12°–16° BTDC (verify with timing light).

Common failure: Sticking piston causing black smoke during acceleration or knocking.

 

 

 

Replaces older Bosch numbers like 0402746657 or 0402746655 (check service manuals for supersessions).

Verify engine serial number compatibility (e.g., Cummins engines with "B" or "C" series codes).

Common Issues & Maintenance:

Failure Points:

Wear in the hydraulic head/rotor.

Sticky advance mechanism (causes hard starting/poor performance).

Seal leaks (leading to fuel contamination or air ingress).

Rebuild Tips:

Requires specialized tools (e.g., dial indicator, pump bench tester).

Always replace wear components (seals, rollers, head/rotor kit).

 

 

 

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