help with 1.6 td inj pump in and out fittings

[frankentoy]

in my rebuild somehow i misplaced the fittings for the front and back side of the injector pump.  correct me if im wrong but the front should have 2 lines going to it? a feed from the filter and a return to the tank? and the back side is the unused fuel from the injectors? which banjo bolts go where? i have 3 actually 2 larger ones , one with a set of large holes and one with a very small hole, then a smaller banjo bolt with a fitting that has about a 2" long steel tube that connects to a fuel line i would imagine but dont see where it goes. it doesnt fit the front or back of the inj pump. its smaller than those holes. is there supposed to be another bajo bolt somewhere im forgetting? thanks

[watsongs]

The large banjo recieves fuel from the filter - that's the only hose.  The return has two hoses - one from the passenger injector, and a large hose that is the return to the tank.  The return banjo hole is the tiny onem to keep fuel pressure in the pump.  When you re-install, replace the copper washers or anneal them, or else they'll leak.  Good luck -

Greg

[moosiah]

Hey ... look at the banjo bolts,,,, the one that goes in the "return " port has "OUT" engraved on it ...... It has a preasure regulator built in to it to to make the advance mechanism work . see " bubbles in my fuel line" posts for what happens if their reversed!!!!! The intake bolt is straight thru........ :wink:

[chrissev]

Hey ... look at the banjo bolts,,,, the one that goes in the "return " port has "OUT" engraved on it ...... It has a preasure regulator built in to it to to make the advance mechanism work . see " bubbles in my fuel line" posts for what happens if their reversed!!!!! The intake bolt is straight thru........ :wink:

If you reverse the banjo bolts the engine will start and run but won't rev at all.  The in bolt has holes in it.  The out bolt doesn't.  There are only two ports that I know of, in and out.  In is near the timing belt, out is on the other side of the pump, at the top on a N/A pump and on the side on a Turbo pump.  The little return lines from the injectors hook up to the out side, on the two way fitting that the out banjo bolt goes through.

[jackbombay]

The in bolt has holes in it.  The out bolt doesn't.

  My out bolt has 1 tiny hole in it, .1-.2 mm or so, and the inside has a tubular screen in it. But I did not think it had a hole for a while because it was so hard to see.

[watsongs]

Jack, you're right - the out has a tiny hole, so small it looks like apiece of dirt...

[chrissev]

The in bolt has holes in it.  The out bolt doesn't.

  My out bolt has 1 tiny hole in it, .1-.2 mm or so, and the inside has a tubular screen in it. But I did not think it had a hole for a while because it was so hard to see.

Yup, it does. I've seen that.  If you blow through the bottom of the bolt, the air comes out that hole.  It seems like most of the fuel return is done through the little rubber lines that go from the injectors with only a small amount of fuel being returned from the pump.

[frankentoy]

thanks everyone. that helps a ton. so just so i get this right. the in or front side is the bolt with the large holes and has only one line going to it. from the filter..and the back side out bolt has the small hole with 2 lines..one from the injectors and one going to the tank? pretty much what Greg said.  how the hell i lost those 2 fittings i dont know. im having a heck of a time finding replacements too. thanks again

[jackbombay]

Yep, you got it right.

  The "in" line is easy, a standard Banjo bolt fitting that is barbed for a hose, the out will need to come off another Diesel. Call some junk yards and see if there are any around, or maybe a Diesel service shop.

[frankentoy]

thank you