Fuel Pump Testing / Calibration (Images / Video)

[Op-Ivy]

Thanks for the amazing insight into the intricateness of these pumps. Makes me want to take mine apart again just for fun  :lol:

[RabbitGTDguy]

All right, I've promised a few people some videos and pictures of the shop so that they could see more clearly what exactly is involved in the testing / calibration of a diesel fuel pump, or so that they can see what we do differently at Performance Diesel Injection versus some of the other pump rebuilders.
We have just been working on TedV's 1.6TD pump, and I've recorded some vids for everyone to see what it is we're DOING when we say that we're testing / calibrating a fuel pump. Before I do that, here are a few images of the shop and test bench.

A shot of the test bench we are using for these fuel pumps.


Giles next to the test bench - I think he believed I was going to do a video, as he appears to be saying something.   :lol:


TedV's 1.6TD pump, fully modified, mounted up and ready for testing.


If you want to see the tests, I've uploaded 4 videos to YouTube; here are the links. These are unscripted, so try not to mind if we don't sound like actors, or if Giles says "variable infinitely drive with planetary gears" instead of "infinitely variable" or something.  

We tried not to make them too "marketing", because we hate being 'sold' stuff too, but we're proud of what we do here, and we have as much fun with it as you do. Hope you guys like these, let me know if you have any questions!

Part 1: Quick tour of the test bench and associated equipment.

Part 2: Testing the "no-boost" fuelling on TedV's pump. Stock or just above stock fuelling at low RPM's with no boost... no smoke.k

Part 3: Testing the "full-boost" fuelling on TedV's pump. 20PSI of boost supplied, huge fuelling increase (~140% ABOVE stock), completely burnable with minimal smoke.

Part 4: We decide to see just how high we can rev this pump without starting to seriously cut out fuel. Turns out ~6500eRPM (Engine RPM) is definitely the maximum here.  :wink:

Enjoy!

Can't believe it took me this long...but was paroosing the IDI forums here tonight and found this. GREAT JOB guys...these are great vids and demonstrations of your modified pumps!!!
 
Joe

[BejamminR]

Wow, the pump looks nothing like the hunk of junk I shipped up there.

I didn't say it!  :wink: Yeah, I spent a pile of time sandblasting that thing. The rust turned the blasting sand from white to brown in one go.  :lol:

And washing the internals with varsol and sandpaper? That was the work of most of the day sometime last week. (Waves his fist) Damn you, oxidation!

[westcoaster]

At any rate, does that answer your question?

Yes you did.
Thank you for your time.


While I have a million more questions swirling around in the back of my mind, now is not the time to be asking them.
I'll be in touch once I tuck into the motor.



Thanks again,

Jarl

[subsonic]

Do you guy's keep records of the pump mod's for each pump you build?  Percent of fuel over stock, etc...?

[BejamminR]

Yes we do.

[BejamminR]

<SNIP>
is Giles gonna train more apprentices so his lost art and knowledge don't go to the grave with him?
also what can i use to make my pump look new like TedV's pump does that wont hurt it?
i hope thats not a trade secrete that you can't share with me either? <SNIP>

Sorry I didn't see this earlier, Duane.
a) He sure is.
b) A sandblaster and blasting sand. There's no magic secret to getting the pumps looking that good - just me spending a long time working on them in the blast cabinet while Giles works on other stuff.
c) Definitely not a trade secret. Varsol will take off a lot of surface grime and stuff, but in order to get the last of the rust off and make the pump shiny and new-looking, a blaster/blast cabinet is the only thing I know of to do the job.

[burn_your_money]

That's what I did when I went for the interview, cleaned up a few pumps.

I wasn't sure if it was a trade secret so I was keeping is hush hush.

[rallydiesel]

Very nice.

[BejamminR]

I wasn't sure if it was a trade secret so I was keeping is hush hush.

Nah, the trade secret is that you're supposed to keep the sand OUTSIDE of the pumps when you blast'em.  :wink: Ssh, don't tell anybody, it might bring us more business.

[TedV]

DOH!  I was in meetings all day with my phone off, looks like I need to make a call in the morning.  :wink:  

Varsol cleans great, but kinda leaves your hands tingly when your glove gets a hole.  I know when the top pump seals leak B20 on a 1Z TDI, then wash with simple green, that will get all the grim off, but won’t touch the oxidation on the steel pump head.  Hey it had 245K miles on the original seals, thanks ULSD. Any trade secrets to keep a pump looking that good, but still make it easy to work on in the future if needed?

[subsonic]

For the setup that you do, do you use standard injectors set to standard TD pop preasures?

 I was wondering how using larger nozzles like the ones for Merc 300TD, or pop preasures that are higher or lower would effect the calibration.

[BejamminR]

There are no automotive injectors on the test bench. There are injection lines, connected to ISO 4010-spec injectors. So hooking up Mercedes injectors or whatever else is not an option on a test bench - automotive are nowhere near precise enough, and they may or may not have the right spray pattern to do the job (in an actual on-engine application, not limited to the test bench there).