Bosch 110/120 Series Basic Disassembly & Extraction Tool Kit – Entry‑Level Service Set For Pump Head & Metering Valve Access

Bosch CP1 and CP2 pumps of the 110 and 120 series are among the most widely used high‑pressure supply pumps in the commercial vehicle and agricultural sectors – fitted to Euro III through Euro V engines from DAF, Iveco, MAN, and many Chinese OEMs. Their hydraulic heads are press‑fitted or retained by a clamping collar, often seized by corrosion and thermal cycling. Workshop technicians routinely resort to improvised methods: jaw pullers clamped onto the pump housing, hammers applied to the head flange, or even heating the housing with a torch. Each of these methods introduces side loads that deform the pump housing bore – typically by 0.03–0.08mm – enough to cause plunger binding during reassembly, leading to premature pump failure within 500 operating hours.

The Bosch 110/120 Basic Disassembly & Extraction Tool Kit provides a controlled, force‑limited approach to removing the hydraulic head and the metering valve (SCV) without inducing distortion. It is an entry‑level set – deliberately simplified, cost‑effective, and focused on the two most common disassembly tasks encountered in a busy diesel workshop.

🔹 Hydraulic Head Puller Assembly

A three‑jaw gripper with hardened steel fingers (48‑52 HRC) that engage the external groove machined into the hydraulic head shoulder – not the head face or the housing lip. The puller includes a central forcing screw with a 17mm hex drive, which applies a pure axial extraction force. A load‑indicator washer – a flat spring that deforms visibly when force exceeds 350 N – provides the technician with a simple visual cue: stop tightening when the washer flattens, indicating the head is fully dislodged.

🔹 SCV Removal Socket

A thin‑walled, deep‑reach socket (22mm A/F) designed specifically for the Bosch metering valve retaining nut. The socket features a lead‑in chamfer that self‑centres on the nut, preventing cross‑threading during removal. The wall thickness is reduced to 2.5mm to clear the surrounding pump casting – a dimension that standard sockets cannot achieve.

🔹 Seal Protector Sleeve

A plastic guide sleeve that fits over the pump shaft during reassembly, protecting the lip seal from damage when sliding the hydraulic head back into position. This prevents the most common assembly‑related failure: lip seal tearing caused by sharp edges on the shaft keyway.

🔹 Anti‑Corrosion Penetrating Oil Applicator

A precision‑tip applicator bottle filled with a dedicated creeping oil formula (viscosity 12 cSt at 40°C) – specifically blended for loosening corrosion‑seized CP1/CP2 fittings. The nozzle is bent at 30° to direct oil precisely into the head‑housing interface gap.

Pump Series	Application	Head Type	SCV Nut Size	Kit Compatibility
CP1H (110)	Medium‑duty trucks	Press‑fit collar	22mm	Full
CP1K (110)	Agricultural tractors	Threaded collar	22mm	Full
CP2 (120)	Heavy‑duty trucks	Press‑fit	22mm	Full
CP2S (120)	High‑output	Press‑fit	22mm (revised)	Full – with SCV adapter

The same basic kit covers the 110 and 120 series – the SCV socket and puller jaws are identical across both families.

Prep – Clean the pump exterior around the hydraulic head joint. Apply penetrating oil via the applicator to the joint gap – allow 5 minutes dwell time.

Pull head – Position the three jaws into the head groove, engage the forcing screw, and tighten using a 17mm wrench. Observe the load‑indicator washer – when it flattens, the head has released. Do not continue turning.

Remove SCV – Insert the thin‑walled socket over the SCV retaining nut, support the pump body with one hand, and turn counter‑clockwise. The socket's lead‑in prevents cross‑threading.

Clean & inspect – Remove the head and valve; clean all mating faces. Inspect the housing bore for scoring – if present, the pump requires more advanced reconditioning beyond this kit's scope.

Reassemble – Place the seal protector sleeve over the shaft, lubricate the new seal with clean diesel oil, and slide the head into position. Torque the retaining collar/clamp to 45 Nm ± 5 Nm.

The puller jaws and forcing screw are manufactured from chromium‑vanadium steel (6150) , hardened to 48–52 HRC and ground to a smooth finish to avoid scratching the pump housing. The SCV socket is produced from 4130 alloy steel, with a black oxide coating that resists corrosion from fuel residue. While the set is designed for occasional workshop use (approximately 200–300 disassembly cycles), it is built to withstand the forces encountered in its specific application – not to replace heavy‑duty hydraulic pullers, but to outlast the workshop's expectation of an entry‑level tool.

Q: Is this tool capable of removing a hydraulic head that is severely seized due to galvanic corrosion?
A: The puller generates up to 500 N of axial force – sufficient for 80% of service cases. For severely seized heads (typically those that have not been removed in over 10 years), we recommend a 24‑hour penetrating oil soak before using the puller. If the load‑indicator washer flattens but the head does not release, stop – the head is likely seized by micro‑welding, and extraction beyond this point could damage the housing. In such cases, a hydraulic head extraction press is required.

Q: Can this kit be used on CP3 pumps (Bosch 110/120 series are CP1/CP2) – are they compatible?
A: No – the CP3 pump uses a different hydraulic head retention system (a bolted flange rather than a press‑fit collar) and a different SCV nut size. The 110 and 120 series specifically refer to the CP1 (single‑piston) and CP2 (two‑piston) pump families. CP3 pumps require a separate dedicated tool set – please contact us for the appropriate kit.

Q: The load‑indicator washer – is it reusable after it flattens?
A: The washer is designed to be reused – it is a spring steel disc (S50C) that returns to its original shape after the load is removed. However, if it shows a permanent set (i.e., it does not return to a slight dome shape when unloaded), replace it. We include an additional washer in the kit as a spare.

Q: What is the correct torque for the SCV retaining nut when reinstalling, and does the socket assist with that?
A: The recommended tightening torque for the SCV nut is 25 Nm ± 3 Nm. The socket is a removal tool – for reinstallation, we recommend using a standard 22mm torque socket, as the thin‑walled socket is not designed for high‑precision torque application. The kit does not include a torque wrench; we assume the workshop has its own.

Q: Can I use the penetrating oil applicator on other components, or is it only for this pump?
A: The applicator contains a formulation specifically for Bosch pump materials (aluminium housing with steel head). It is safe for use on other diesel components, but we recommend it for this application only – other components may have different seal materials or coatings that could react. For general use, any good‑quality penetrating oil will suffice.

Q: Does this kit include instructions for reassembly, including seal replacement and lubrication?
A: Yes – the kit includes a 12‑page illustrated guide that covers both disassembly and reassembly, with torque values, seal orientation diagrams, and a lubrication points chart. A QR code on the guide links to a video showing the entire procedure – accessible on mobile.

 

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