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Off Topics > Diesel injection pump rebuild.....
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada

Well my good ol' MK1's injector pump gave in and started puking fuel all over so I toke it off and sent it for a "performace" rebuild along with the injectors. We did a compression check since we;re at it, and 3 cylinders came back between 497-501 and one at 484 while cold. Is that difference acceptable? didn't even realize one glow plug was dead and still started fine.....
any thoughts on putting the pump back on and timing it? I dont think it has ever been timed cause we had to use "the force"to get it off once all the bolts were removed. Also is there an effective way of cleaning the engine? As you can see when the car was rust proofed a million years ago they sprayed the whole engine.....
thanx



No honey I got that used.... MAAC#73745
10-08-2008 03:00 PM
 
 
Sig Dawg
Senior Heliman
Location: Weyburn, Sask., Canada

Check out tdiclub.com You'll find all the info you need there, and there is probably someone in your area there who is a guru who would be willing to help you out.

Good luck

Jason - diesel power rocks (VW TDI)
10-08-2008 03:18 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

Vw compression

Thats not a big enough difference on an old diesel to worry about.Did you align the timing marks before you removed the drive belt?Is that engine the 1.9 litre diesel or a 1.6?
10-08-2008 03:23 PM
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada

it's a 1.6. Yeah I marked everything as much as I could. I'm getting the injectors rebuilt while I'm at it cause I dont know what to look for just by eyeballing it..... Damn no trex 500 for me this month either.... The rebuild of the stuff is gonna be around $1100

No honey I got that used.... MAAC#73745
10-08-2008 03:27 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

Vw compression

I dont know how much you know about diesels so forgive me for being basic.Did you put the engine on the compression stroke for no1 cylinder before you took the belt off.Do not make any attempt to turn the engine over with the belt off.If you need timing mark details i have them.Is your engine turbo or normally aspirated.
10-08-2008 03:39 PM
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada

Obviously I did the compression test with the belt on.... I'm not my wife.

No turbo on this puppy.... 0-60 is about 45 secs I'm hoping with the performace rebuild maybe It'll be about 42.5...

No honey I got that used.... MAAC#73745
10-08-2008 03:43 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

Vw compression

Sorry no offence meant by that,but i do get the odd person come in my shop saying they have just changed that cogged belt thingy and now it wont start.When i ask them about retiming the motor they give me a blank look and say well i fitted an alternator belt and didnt have to do that,is this one not the same?
10-08-2008 03:49 PM
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada

NOOOOO You cannot be serious

No honey I got that used.... MAAC#73745
10-08-2008 03:52 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

Vw compression

Totally,i could tell you some stories,believe me.
10-08-2008 03:55 PM
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada

Thanx I'd appreciate some marking details if you got them. Worst comes to worst I'll just get it towed to a fellow RR memeber who just happens to be a VW mechanic, but of course I work about 35miles from home and I really don't have the $$ to pay for towing so I'm trying to keep it a DIY project. At least on this one I can see everything with tonnes of room in the engine compartment, unlike on the Wife's 1.8T late model passat.... When that refused to start once due to some elctronic issues I didn't even bother with opening it... notlike I could see anyting, just towed it to the dealer

No honey I got that used.... MAAC#73745
10-08-2008 04:04 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

Vw compression

If you remove the camshaft cover first you will see at the opposite end of the camshaft there is a slot cut into the end flange(Opposite end to the cam belt wheel.You need to set the engine so it is at T.d.c on compression stroke on No1 cylinder.On the gearbox there is a round plastic plug which can be unscrewed to show a pointer which will align with another on the flywheel when the pistons of 1 and 4 cyls are at the very top of there stroke.With the belt removed first set the pistons so that they are all equally set halfway down each bore.You will have to be careful you do not get any valve to piston contact with the belt removed.Set the camshaft so the valves are closed on no1 cylinder end you will see the the slot in the rear cam flange will be pefectly parallel with the flat face of the cyl head.Use a straight edge to get this just right(Important).Then turn the crank so the pistons of 1 and 4 are at the top of their cyls and the mark on the flywheel should be aligned with the pointer.The injection pump wheel has a hole in it that aligns perfectly with a hole in the pump body(a drill bit or similar of the right diameter can be used to keep these marks aligned.When fitting the belt knock the cam wheel off its taper to allow the slot in the cam to stay in the right place then resecure it to the cam and double check all marks are perfectly aligned.
10-08-2008 04:43 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

Vw compression

Any questions please ask,will photo my info on marks and post later.
10-08-2008 04:45 PM
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada



thanx
I'll have to read it 3 times slowly so I'll understand

No honey I got that used.... MAAC#73745
10-08-2008 05:03 PM
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada

Well I got the pump back, so $1100 later I got a very nice injector pump and set of injectors with Mercedes 300D nozzles
Now I just need to figure out the timing. I'm gonna do it myself cause I really dont have the money to pay someone....

Pix here:
http://s499.photobucket.com/albums/...984jettarepair/

No honey I got that used.... MAAC#73745
10-15-2008 04:18 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

VW Diesel

Take your time Zozie if you are careful you should be Ok.The most important thing is to make sure you line everything up just so.On a diesel engine the running clearances between the valves and pistons are Minimal so the timing has to be spot on otherwise you will end up with a lot of bent valves or worse.Leave the injectors out until you have fitted the belt so you can rotate the crankshaft by hand to make sure you have the mechanical timing correct and no fouling of any parts.
10-15-2008 05:12 PM
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada

Thanx. According to the shop I gotta go with 0.95 advanced timing for the pump to work good

No honey I got that used.... MAAC#73745
10-15-2008 05:57 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

VW Diesel

If you initially fit the pump you can alter the timing after it is fitted via the slots in the pump body which allow for this.You need special equipment to set it precisely but on the marks wont be far out to start with.If it is too far advanced the engine will have a really heavy diesel knock.
10-16-2008 10:45 AM
 
 
zozie
Senior Heliman
Location: Mississauga, Ontario, Canada

Well I got it all back togther, managed to time it, I cranked it but it wasn't picking up the fuel properly all I got was bubbles in the line so I gotta figure out how to prime the pump. Just by the size of it I'd say it hold abooot a liter......

No honey I got that used.... MAAC#73745
10-17-2008 11:46 AM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

VW Diesel

Hi Zozie,if your new pump is completely empty you really do need to get all of the air out of the system.Do you have a primer pump on the top of the fuel filter housing, if you do you can take the return pipe off the injection pump and hand prime till the diesel comes out air free.If not you might find it easier to fill the pump by hand through the inlet until the fuel flows out of the fuel tank return line.If your fuel filter is empty it will be best to make sure this is full of fuel first by filling in the same way.Getting all the air out is essential for the motor to have any chance of starting so take your time and be patient.Once you think you have cleared all the air ,if you loosen a couple of the injector pipes whilst cranking the motor you should get diesel ejected under some pressure.Once you have this on all the pipes you should be good to go.Bleeding air from a empty diesel system after a strip down can be a pain so be thorough.Regards Mike.Word of warning,if you have to hand prime the pump,make sure you use clean diesel from a spotlessly clean container because dirt entering the pump will damage it.
10-17-2008 12:15 PM
 
 
shawmcky
Senior Heliman
Location: Isle of Wight,United Kingdom

VW Diesel

If you have access to a vacuum pump of some description this will help to draw the fuel by dragging it through the system.A hand help petrol pump as used for Heli,s might suffice if you have one.Be best to clean it after though of course.If your filter is the screw on type remove it and fill it to the brim if it is new (or used )carefully refit it without spilling.The filter must be full before you try and prime the pump.You can draw the fuel through till it is air free by attaching it to a vacuum pump or fuel pump using the supply pipe to the pump and refitting it to the pump when clear of air.
10-17-2008 12:27 PM
 
 
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Off Topics > Diesel injection pump rebuild.....
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