Author Topic: pump and injector rebuilds (Read 4347 times)

ejust · « **on:** July 22, 2005, 09:49:33 am »

ive got the mpg thread going to figure why my milage sux in comparison to most of you and yet i drive steady and try to be efficient. only once in a while do i have a wild hair and drive spirited. So if i have parts that are shot... im thinking rebuild. How bad is it to rebuild a pump and injectors. I dont have much money to spend so i try to fix everything i can to keep my cars running.

Suggestions especially from the pros......

?

Justin · « **Reply #1 on:** July 24, 2005, 10:04:31 pm »

i am no pro, but taking apart the pump and chem diping everything and then replacing the seals and putting the pump back together is pretty straight forward, i did this with a pump that didnt work and when i put it back together it worked, i would say that if it runs then the injectors are probably your problem, but i dont know for sure and have you checked your compression lately?

ejust · « **Reply #2 on:** August 01, 2005, 02:41:42 pm »

are there any of the experts willing to share some info on rebuilding, pricing, and setting the pump (basic settings and for economy)..
Plz help thanks

Justin · « **Reply #3 on:** August 02, 2005, 08:06:40 pm »

as far as settings take a look in the bentley and ussually advancing it gives you a little more power and economy, you can also back out the smoke screw for less fuel and better economy. you can also keep your foot out of the right pedal, and like i said bad injector nozzles can cause poor performance and milage

later
justin

janb · « **Reply #4 on:** August 02, 2005, 11:13:49 pm »

do some searching on the forum, there was a pretty complete BOSCH manual published and posted awhile back.

I have not done a pump YET, but have the seal kits $16

Of course precision and clean is very important, and doing a Pump bench test and calibration would be good. Probably you could rig this up on a milling machine or lathe. To buy these services is USD$200-$600 (You can usually get a new pump for $600)

I usually have pretty good luck with injectors by just replacing tips ($7ea@dealer price, but you should find for under $10) BOSCH
be sure to have clean and tight, and keep shims with correct body.

You can have injectors tested (spray pattern and break pressure) for free at most bosch shops

chrissev · « **Reply #5 on:** August 03, 2005, 05:19:01 am »

Quote from: "janb"

do some searching on the forum, there was a pretty complete BOSCH manual published and posted awhile back.

I have not done a pump YET, but have the seal kits $16

Of course precision and clean is very important, and doing a Pump bench test and calibration would be good. Probably you could rig this up on a milling machine or lathe. To buy these services is USD$200-$600 (You can usually get a new pump for $600)

I usually have pretty good luck with injectors by just replacing tips ($7ea@dealer price, but you should find for under $10) BOSCH
be sure to have clean and tight, and keep shims with correct body.

You can have injectors tested (spray pattern and break pressure) for free at most bosch shops

where can you get a new pump for $600? Rebuilt ones are usually more than that I thought? That is an awesome price

watsongs · « **Reply #6 on:** August 03, 2005, 11:02:44 am »

Jan - where are you getting your injectors tested? My local bosch shop charges $46 for four injectors.

janb · « **Reply #7 on:** August 05, 2005, 11:03:16 pm »

Quote

Jan - where are you getting your injectors tested?

Diesel Fuel Injection Service
(503) 239-1547 (Portland, OR)
I used to do the testing myself, (while they were on lunch break) but the main man retired .... they weren't too impressed last time I brought 30+ injectors in, so they still let me do it. (from my experience, most injectors test OK, unless there is noticable 'off center wear, or a crunched needle) It would be easy to build a test station for injectors (from old Hyd jack + gauge)

I found a great diesel shop in Seattle, when looking for info on my 1.9 injectors, but I don't have contact anymore.

for the new $600 pump, they were ~$580 last I checked at Halsey Import parts, (couple years ago (stronger $USD)
503-256-0182 1-800-792-0081 (that was before I had a commercial account, I'll check again, next time I'm in... tomorrow...)

$624 new/ no core here
http://www.germanautoparts.com/Volkswagen/Jetta/Fuel/67/2

or... if you have really tough skin, and are not faint of heart or emotion
http://www.partsplaceinc.com

Jack's rebuilds are $325 NA or $495 TD
https://webinsi5.securesites.com/vwdiesel/ordform.htm

ejust · « **Reply #8 on:** August 06, 2005, 09:14:45 am »

cost me 35-40 just to check pressures
have no idea what it wold cost to rebuild injectors or pump

Car has 222K mi(357k km) so im about due id say. Dont think the injectors are spraying evenly anymore

Im sure the pump needs new seals and such

janb · « **Reply #9 on:** August 06, 2005, 11:30:18 am »

Quote from: "ejust"

cost me 35-40 just to check pressures
have no idea what it wold cost to rebuild injectors or pump

Car has 222K mi(357k km) so im about due id say. Dont think the injectors are spraying evenly anymore

Im sure the pump needs new seals and such

222k is not much, pumps can go 500k+. Injectors 300k+ (clean fresh fuel is key, and additve helps prolong)
If pump is not leaking, and engine has performance through power band it is likely working ok, pumps usually have catastrophic failure.

here are some $8.50 injector nozzles
http://www.autohausaz.com/catalog/lookup_parts.cfm?SubcategoryID=6096&VehicleID=1282788&CFID=514782&CFToken=86773632

new nozzles often really smooth out a rough running engine BUT not necessarily is your problem.

What is you mileage, and vehicle, and driving habits?; I have some IDI's that get 50MPG and some that get 40mpg.

1) Check rolling resistance (dragging brakes / cv's...poor tires(run max PSI))
2) Have clean filters and plenty of fresh cool air to intake )+ big exhaust
3) check valves if mechanical
4) check pump timing, error to lean (~0.8mm)
5) check fueling volume, tweak to make minor smoke at WOT
http://www.cs.rochester.edu/u/jag/vw/engine/fi/injpump.html
6) minimize throttle action by shifting minimal, and holding steady enroute
7) use synthetic oil in engine and tranny

lose wieght (car and driver)
9) minimize air drag (wash and wax. add belly pan/ fairings or air dams)
10) use good fuel conditioner (I get best mileage increase with 'red-line' diesel additive, but not available in PNW, so I use Stanadyne performance)
...
21) get another inj pump off friend, junkyard or eBay and try that. (I do feel pumps are a significant contributor to mileage BUT they are tough to swap, just for the fun of it... :oops:

good luck

janb · « **Reply #10 on:** August 06, 2005, 10:59:22 pm »

that pic location looks familiar (John Day Solwest?) Was just there last week

so ... what was result of that contraption? I still think it would be possible to make a 75MPG vw-D Scirocco, but haven't tried yet. The Honda Insight guy displaying 87mpg needs some competition. I did blast past him near Pendelton, as he usually drives 55mph (Admittedly, I was only getting 52 mpg @ 80 mph w/AC... in '97 Passat TDI) :wink: [/quote]