Fuel Injection Pump Repair for Medium and Large Diesel Engines

Overhaul, Testing and Spare Parts for Marine, Industrial and Power-Generation Engines

Einspritzpumpen Manufaktur NRW is a specialist workshop in Germany for the overhaul, repair, testing and technical restoration of mechanical fuel injection pumps used in medium and large diesel engines.

Our services cover fuel injection systems for:

• marine propulsion engines
• marine main and auxiliary engines
• generator sets
• emergency power systems
• stationary power plants
• industrial diesel engines
• railway locomotives
• compressor and pump drives
• mining equipment
• heavy-duty machinery
• and other large-engine applications

Our principal areas of expertise include Bosch P9 and Bosch P10 inline fuel injection pumps, injection pumps for Deutz 528 and 628 engines, and L’Orange injection systems for MWM TBD440 and TBD441 engines.

We provide technical identification, complete dismantling, component inspection, precision measurement, replacement-part supply, reverse engineering, professional reassembly and test-bench calibration.

Precision Fuel Injection for Reliable Large-Engine Operation

A large diesel fuel injection pump is a heavily loaded precision assembly. It must deliver an accurately defined quantity of fuel to every cylinder under changing engine-speed and load conditions.

Even comparatively small deviations between the individual pump sections can affect:

• engine output
• fuel consumption
• combustion quality
• exhaust-gas temperatures
• cylinder balance
• engine smoothness
• component service life
• and overall operational reliability

Professional overhaul therefore involves considerably more than replacing seals or repairing an external fuel leak.

Reliable restoration requires:

• unambiguous technical identification
• complete dismantling
• controlled cleaning
• dimensional inspection
• assessment of all functional components
• suitable replacement parts
• precise mechanical assembly
• and final calibration on an appropriate fuel injection pump test bench

This is exactly what our workshop is equipped to provide.

Specialist Knowledge for Different Large-Engine Injection Systems

The term “large diesel fuel injection system” covers a wide range of mechanically and technically different pump designs.

The correct injection pump depends on factors such as:

• engine manufacturer
• engine series
• number of cylinders
• rated output
• rated speed
• direction of rotation
• marine or industrial application
• production version
• and technical modification level

For this reason, we do not apply a standardised repair procedure to every large-engine injection pump.

Our main specialist fields are:

• Bosch P9 inline fuel injection pumps
• Bosch P10 inline fuel injection pumps
• injection pumps for Deutz 528 and 628 engines
• L’Orange injection pumps for MWM TBD440 and TBD441 engines
• associated plug-in pumps and injection components
• additional mechanical large-engine fuel injection systems following technical assessment

Each injection pump is evaluated according to its individual design, identification numbers, technical condition and engine application.

Bosch P9 Inline Fuel Injection Pump Overhaul

Bosch P9 inline fuel injection pumps were developed for high-output industrial, marine and stationary diesel engines.

Their large pump elements, robust mechanical construction and numerous application-specific versions require specialist knowledge during dismantling, dimensional inspection, spare-parts identification and test-bench calibration.

Frequently requested Bosch P9 pump types include:

• FA-PE8/9M/160/100/LV
• FA-PE8/9M/180/100S24

The same pump designations may appear in technical documentation or online searches without spaces, slashes or hyphens, for example:

• FAPE89M160100LV
• FAPE89M180100S24

Frequently requested Bosch P9 part numbers include:

• B 405 980 021
• B 405 980 022
• B 405 980 023
• B 405 980 024

Alternative written forms such as B405980024 or B-405-980-024 may refer to the same Bosch part number.

Our services for Bosch P9 injection pumps include:

• identification of the exact pump version
• complete dismantling and cleaning
• inspection of the pump elements
• camshaft and tappet inspection
• bearing and housing inspection
• replacement or reproduction of worn components
• professional reassembly
• calibration of all pump sections
• and final test-bench verification

A binding identification is always based on the complete Bosch pump designation, the Bosch part number, available engine-manufacturer references and the technical data of the associated engine.

Bosch P9 Fuel Injection Pump Overhaul and Calibration

Bosch P10 Inline Fuel Injection Pump Repair

The overhaul and calibration of mechanical Bosch P10 inline fuel injection pumps is another central area of our work.

These pumps are used in numerous high-output MWM and Deutz engines for marine propulsion, industrial installations, generator sets and stationary power-generation applications.

Bosch P10 pump types handled or regularly requested include:

• PE8/10/150/100LS50
• PE8/10/150/100LS51
• PE8/10/150/100LS52
• PE8/10/150/100LS53
• FA-PE6/10/160/300RS34
• FA-PE12/10/160/100LS43

Known Bosch part numbers include:

• 9 410 365 828
• 9 410 365 829
• 9 410 365 830
• 9 410 365 831

The compact number 9410365831, for example, may represent the same Bosch reference as 9 410 365 831.

Associated MWM and Deutz OEM references include:

• 12302170
• 12302171
• 12302838
• 12302839

These references may also appear in forms such as:

• 1230 2170
• 1230-2170
• 1230 2838
• 1230-2838

P9 and P10 Applications in MWM and Deutz Engines

The MWM/Deutz TBD604 engine family was produced as an inline six-cylinder engine and in V8, V12 and V16 configurations. These engines used the lower-output P10 injection-pump system.

The MWM/Deutz TBD620 and TCD2020 engine families were produced as V8, V12 and V16 engines. Depending on the engine version and power rating, they were equipped with Bosch P10 or Bosch P9 injection pumps.

The engine-series designation alone is therefore not sufficient for reliable pump identification. The complete pump type, part number, engine version, rated output and rated speed must also be considered.

Injection Pumps for Deutz 528 and 628 Engines

We also provide technical identification, overhaul and component support for mechanical injection pumps used in historical Deutz 528 and 628 large diesel engines.

Known engine configurations within the 628 family include:

• SBV6M628
• SBV8M628
• SBV9M628
• SBV12M628
• SBV16M628

Different injection-pump versions were used depending on:

• number of cylinders
• engine configuration
• direction of rotation
• rated output
• engine speed
• application
• and technical production status

Known Deutz part numbers associated with SBVM628 fuel injection pumps include:

• 02128724
• 02128708
• 02128710
• 02125802
• 02128229
• 04093601
• 02125803
• 02125822
• 04093605
• 02125823

The same Deutz reference may be written in several forms. For example:

• 02128724
• 0212 8724
• 0212-8724

For Deutz 528 and 628 engines, the fuel injection pump and the engine governor are separate assemblies. The Woodward governor is mounted separately on the engine and is not part of the injection pump.

Our services include:

• identification of the injection pump
• recording of all part numbers
• complete dismantling
• component cleaning
• dimensional inspection
• repair or replacement of worn parts
• spare-parts identification
• professional reassembly
• and functional testing

The exact pump version is determined from the Deutz part number, complete engine designation, direction of rotation and available technical documentation.

L’Orange Injection Pumps for MWM TBD440 and TBD441

L’Orange fuel injection systems were used in various configurations on MWM and Deutz-MWM large diesel engines of the TBD440 and TBD441 families.

Known engine variants include:

MWM TBD440

• TBD440L6
• TBD440L8
• TBD440V12
• TBD440V16
• TBD440V12K
• TBD440V16K

MWM TBD441

• TBD441L6
• TBD441L8
• TBD441V12
• TBD441V16
• TBD441V12K
• TBD441V16K

A number of L’Orange pump and plug-in pump designations are associated with these engine families, including:

• PYY-G012B and PYY-G012S
• PYY-G014B and PYY-G014S
• PYY-G018B and PYY-G018S
• PYO-G018R and PYO-G018L
• PYO-G028R and PYO-G028L
• PYO-U091R and PYO-U091L
• PYO-U117R and PYO-U117L

For the corresponding marine PYY versions, the suffix letters B and S identify the engine side:

• B designates the port-engine version.
• S designates the starboard-engine version.

The pumps are configured for their respective installation position and operating direction. A port-engine pump must therefore not be replaced by a starboard-engine version, or vice versa, without a complete technical assessment.

Known MWM and Deutz references associated with the 440 engine family include:

• 12152577
• 12152581
• 12152583
• 12152584
• 12172044
• 12172046
• 12172051
• 12172064
• 12172065

Longer MWM NMR identification numbers may also be relevant, including:

• 6.440.0.725.069.7
• 6.440.8.725.008.7

Our workshop provides identification, dismantling, dimensional inspection, overhaul and testing of historical L’Orange injection pumps, associated plug-in pumps and individual pump components.

Technical Identification by Nameplate and Part Number

For historical large-engine fuel injection pumps, the general engine-manufacturer name is rarely sufficient for reliable identification.

Depending on the engine version and production status, visually similar pumps may contain different:

• plunger-and-barrel assemblies
• delivery specifications
• camshafts
• cam profiles
• drive arrangements
• directions of rotation
• mounting positions
• control mechanisms
• and manufacturer references

For an initial technical assessment, we therefore require as much of the following information as possible:

• complete injection-pump type designation
• pump manufacturer
• Bosch, Deutz, MWM or L’Orange part number
• exact engine designation
• number of cylinders
• rated engine speed
• rated engine output
• field of application
• clear photographs of the nameplate
• photographs of the complete injection pump
• and, where available, spare-parts lists or test specifications

For marine installations, please also specify whether the pump belongs to the port or starboard engine.

The more complete the information, the more reliably we can identify the pump, assess the required overhaul work and determine the correct replacement components.

Professional Overhaul of Large Diesel Fuel Injection Pumps

The exact procedure depends on the injection-pump design, technical condition and availability of technical specifications.

A typical overhaul includes the following stages.

1. Incoming Inspection and Documentation

The pump is documented in its delivered condition.

We record:

• nameplate data
• part numbers
• direction of rotation
• attached components
• visible damage
• corrosion
• fuel or oil leakage
• and indications of previous repair work

The original condition often provides important information about the cause of failure.

2. Controlled Dismantling

The injection pump is completely dismantled or separated into its principal functional assemblies.

Installation positions, mechanical settings and component relationships are documented before the parts are removed.

3. Multi-Stage Cleaning

Pump housings, plunger-and-barrel assemblies, camshafts, tappets, rollers, bearings and other components are cleaned using appropriate industrial processes.

Fuel residues, lubricating oil, corrosion products and deposits must be removed before reliable inspection and measurement can take place.

4. Visual Inspection and Precision Measurement

Depending on the pump design, we inspect and measure components including:

• pump elements
• plungers and barrels
• delivery valves
• camshafts
• cam profiles
• rollers and tappets
• bearings and bushes
• shafts
• sealing surfaces
• actuating components
• control racks
• control sleeves
• adjustment mechanisms
• housing bores and fits
• springs
• and connecting components

Only components whose technical condition permits reliable continued operation are reused.

5. Repair or Replacement of Worn Components

Worn or damaged parts are:

• replaced with suitable components
• professionally reconditioned
• repaired where technically permissible
• or reconstructed and reproduced through reverse engineering

The selected procedure depends on component function, material, dimensional condition and operational loading.

6. Precision Reassembly

The injection pump is reassembled under controlled workshop conditions.

Mechanical clearances, component positions, control mechanisms and basic settings are adjusted according to the pump design and available technical information.

7. Test-Bench Operation and Calibration

Following assembly, the injection pump is operated on a suitable fuel injection pump test bench.

Depending on pump type and available calibration data, the following parameters can be examined and adjusted:

• fuel delivery of each pump section
• uniformity between individual cylinders
• start of delivery
• delivery behaviour at different pump speeds
• low-speed and rated-speed operation
• mechanical actuation
• control-rack operation
• leakage
• adjustment mechanisms
• repeatability of delivery quantities
• and interaction between multiple pump units

8. Final Inspection and Documentation

After successful testing, the injection pump undergoes a final technical inspection.

The pump is released for continued service only after its mechanical operation and relevant test values have been verified.

Fuel Injection Pump Test-Bench Capability up to 16 Cylinders

Accurate fuel injection pump calibration directly affects:

• engine output
• fuel consumption
• combustion quality
• cylinder-to-cylinder balance
• exhaust-gas temperatures
• smooth engine operation
• operational reliability
• and engine service life

Our workshop has specialist test-bench equipment for mechanical inline fuel injection pumps and large diesel injection systems.

One test bench allows the inspection and calibration of inline injection pumps with up to twelve pump sections.

For particularly large injection systems, we also operate a specially designed 16-cylinder fuel injection pump test bench.

Its technical features include:

• an extended pump bed
• increased rotating mass
• a high-capacity drive system
• mounting capability for large inline injection pumps
• and testing of complete tandem pump assemblies

Tandem Injection Pump Testing and Synchronisation

Large V16 diesel engines may use two mechanically coupled injection pumps operating together as a tandem assembly.

The two pumps can first be inspected and calibrated individually. They can then be installed as a complete tandem assembly and synchronised on the 16-cylinder test bench.

Typical tandem applications include:

• MTU 396 V16
• Deutz/MWM TBD620 V16
• Deutz/MWM TCD2020 V16

Correct synchronisation of both pumps is essential for:

• uniform fuel delivery
• minimum cylinder-to-cylinder deviation
• balanced exhaust-gas temperatures
• smooth engine operation
• reliable load acceptance
• and long-term operational safety

Testing only the individual pumps does not fully verify their interaction as a mechanically coupled tandem system.

Reverse Engineering of Obsolete Injection Pump Components

Original replacement parts for many historical large diesel fuel injection pumps are now available only in limited quantities or have been discontinued completely.

However, a single unavailable component should not necessarily result in the shutdown of an otherwise serviceable engine, vessel or industrial installation.

Where technically and economically feasible, original components can be:

• accurately measured
• technically documented
• reconstructed in CAD
• analysed according to their function
• specified with suitable materials
• reproduced by specialised European manufacturers
• and inspected before installation

Depending on the component, the reverse-engineering process considers:

• component function
• dimensional accuracy
• material specification
• hardness
• heat treatment
• surface finish
• fits and tolerances
• mechanical loading
• thermal loading
• wear behaviour
• and long-term operational reliability

The technical and commercial feasibility of reproduction is assessed separately for each component.

Spare Parts and In-House Stock

Our own stock includes numerous wear parts and replacement components for historical mechanical fuel injection pumps.

Depending on the pump system, available parts may include:

• plunger-and-barrel assemblies
• pump elements
• delivery valves
• bearings and bushes
• rollers and tappets
• seals and shaft seals
• springs
• actuating components
• control sleeves
• plug-in pumps
• housing components
• and specially reproduced replacement parts

Components that are not immediately available can be sourced, reconditioned or newly manufactured where technically feasible.

Our own stock and access to specialised European manufacturing capacity help reduce unnecessary downtime, particularly for industrial, marine and power-generation applications.

Why Choose Einspritzpumpen Manufaktur NRW?

Our work combines traditional mechanical large-diesel injection technology with modern measurement methods, specialist test equipment and independent component development.

Our capabilities include:

• specialist knowledge of historical mechanical large-engine injection pumps
• overhaul of Bosch P9 injection pumps
• overhaul of Bosch P10 injection pumps
• experience with Deutz 528 and 628 injection systems
• overhaul of L’Orange systems for MWM TBD440 and TBD441
• test-bench capability for pumps with up to 16 cylinders
• testing and synchronisation of tandem pump assemblies
• precision component measurement
• replacement-part identification
• in-house spare-parts stock
• reverse engineering
• European replacement-part manufacturing
• and individual technical assessment of every injection pump

We do not provide an anonymous standard exchange repair.

Every pump is evaluated according to its exact design, technical condition, identification numbers and engine application.

Frequently Asked Questions

Which large diesel fuel injection pumps do you overhaul?

We overhaul mechanical Bosch P9 and P10 inline injection pumps, injection pumps for Deutz 528 and 628 engines, and L’Orange injection pumps and plug-in pumps for MWM TBD440 and TBD441 engines.

Other mechanical large-engine injection systems can be submitted for technical assessment.

Can you identify an injection pump from the part number alone?

A part number is an important starting point, but it is not always sufficient for a binding identification.

We also require clear photographs of the nameplate, pictures of the complete pump and information about the corresponding engine.

Are injection pumps calibrated after overhaul?

Yes. A mechanically overhauled injection pump is tested and calibrated on a suitable test bench according to the available technical specifications.

Can discontinued injection pump components be reproduced?

Many unavailable components can be measured, technically reconstructed and manufactured by specialised European production partners.

Feasibility depends on the function, material, dimensions, required tolerances and operating load of the component.

Can you test complete 16-cylinder tandem injection pumps?

Depending on pump design, mounting configuration and available test data, complete tandem pump assemblies can be tested and synchronised on our specially designed 16-cylinder test bench.

Do you repair injection pumps for marine engines?

Yes. We overhaul mechanical fuel injection pumps for marine propulsion engines, auxiliary engines and other maritime applications.

For L’Orange marine pumps, port and starboard versions must be identified correctly.

Do you repair both Bosch P9 and Bosch P10 injection pumps?

Yes. Bosch P9 and Bosch P10 inline fuel injection pumps are central areas of our workshop expertise.

The exact overhaul capability depends on the pump version, technical condition and availability or reproducibility of the required components.

Can international customers send an injection pump to Germany?

International enquiries are welcome. Please send the pump identification details and photographs before shipping so that we can carry out an initial technical assessment and provide suitable delivery information.

Request an Assessment of Your Large Diesel Injection Pump

For an initial technical evaluation, please provide:

• manufacturer of the injection pump
• complete pump type designation
• all part and reference numbers
• exact engine designation
• engine manufacturer
• number of cylinders
• rated output
• rated speed
• engine application
• photographs of all nameplates
• photographs of the complete injection pump from several angles
• a brief description of the fault
• information about previous repairs
• and any available spare-parts lists or test specifications

Please do not dismantle or unnecessarily clean the injection pump before contacting us.

Its original condition may provide important evidence of leakage, corrosion, wear or previous mechanical intervention.

After reviewing the information, we will provide an initial technical assessment and an individual quotation based on the actual pump and required work.

Contact Our Large Diesel Fuel Injection Specialists

Name 

Company

Country

Email Address 

Telephone Number

Engine Manufacturer and Type

Injection Pump Manufacturer

Pump Type or Part Number

Description of the Fault 

Submit Technical Enquiry

Einspritzpumpen Manufaktur NRW

Specialist for Medium and Large Diesel Fuel Injection Systems

Professional overhaul, repair, testing, calibration and replacement-part support for:

Bosch P9 · Bosch P10 · Deutz 528 and 628 · L’Orange TBD440 and TBD441

Specialist services for marine propulsion engines, industrial diesel engines, generator sets, power-generation installations and stationary large-engine applications.

Request a Large Diesel Injection Pump Assessment