Fuel Injector Repair: DIY Guide & Tips

Is it possible to repair or overhaul a (purely mechanical) axial distributor injection pump – brand: Bosch – yourself? Does anyone know if there are any repair kits available?

"Please provide more information..."

Which pump, from which car, and with what problem?

Hi there,
You can find quite a bit of repair information online by using the right search terms (e.g., "distributor injection pump," "reconditioning," etc.), especially for Bosch VP pumps within the VW T3 and T4 communities.
Here in the forum, we have a guide on how to repair the high-pressure part, which at least shows the basic principle for older pumps.
Using the Bosch part number of the pump should at least allow you to identify compatible repair kits, and usually also make them orderable.
hg
Herbert.

It's a classic Ford Escort 1.8D without a turbocharger.

Problem history:
Cold start - poorer throttle response than usual - 10 minutes.
Highway driving - slight engine vibration similar to when the fuel tank is almost empty.
empty or with air bubbles somewhere in the system - increasingly less often.
Power - 5th gear - 4th gear - 3rd gear - 2nd gear - Shoulder of the road (or hard shoulder).
The engine won't start anymore - the police are arriving soon .
- Towing service !

Hi!

Well, I'd need to sort out a lot of other things first.

That sounds like a problem with the fuel supply.
Hey, does the Ford have a metal fuel tank?

Air vent, diesel filter, preheating...
Air in the suction line?
hg
Herbert.

PS: "Bullen" (literally "cows," but in this context, it refers to police officers) are your friends and helpers. We call them "Rennleitung" (a term for traffic control). For example, on the highway, they secure your vehicle if you have a breakdown.

I was exactly 100 meters away from the highway exit.
Holding a tow rope, wearing a high-visibility vest, and...
"Nothing will stop me from walking those few meters."
to pull out!
It's just like that these days, unfortunately.

Ja, der Ford hat noch einen Blechtank. Sure, here is the translation of the text from German to English:

"A"
Thick filling hose, definitely 2 or 3.
small hoses between the tank and the fuel filler neck.
whose exact functions are not entirely clear to me.
are located, along with a (presumed) vent valve.
located under the rear fender, near...
located at the filler neck.

The preheating is achieved using a diesel filter with...
Metallgehäuse, der am Motor angeflanscht ist. From
This leads directly to the fuel injection pump, which...
The fuel is self-priming.

No air bubbles were detected in the pipeline.
I have this small, transparent pre-filter.
Between the fuel tank and the main filter.
The main filter is brand new and completely full of diesel.
(this is visible when you look at the vent screw)
or unscrews the fill screw on the filter).

I would also like to mention that this happened about a week before...
a brief, intense (a fraction of a)
Second-long engine cutouts during driving.
It had a problem before, but everything is back to normal now.

Is the solenoid valve energized and opening as it should?

If necessary, you can remove the small piston, pull it out slightly, and reinstall it. This will help rule out that component as the cause of the problem. If the engine starts, it must be manually shut off to stop it from running.

Trying to use Fall Diesel.

Regarding the diesel fuel quality test: To my knowledge, my ESP (Emissions System Performance) consists of two parts. First, the fuel is drawn from the tank...
It is drawn through a filter from what is called an impeller pump and then flows into the high-pressure pump.
Now, with the engine running (without engaging the starter), several drops of diesel are constantly leaking from the return line of the electronic stability program (ESP).
With the starter engaged and the injector caps open, not much changes in that regard.
A small amount of diesel may leak from the fuel injectors, but it does so without pressure.
My question is: Doesn't a much larger amount of diesel fuel come out of the return line when the starter motor is activated?

Hello!

To be honest, I've never checked the amount of backflow. And what you tested seems illogical to me in relation to your problem, or I just can't properly assess it.

I can only tell you this because I inquired about metal tanks:
In relatively old cars with metal fuel tanks, significant rust can form inside, which is further accelerated by current fuels.

It is not uncommon for rust to accumulate on the filter screen inside the tank, which can restrict fuel flow.

When the engine is stationary, rust can sometimes slowly flake off. This gradual loss of power, leading to eventual failure of the drive system, is a very common problem.

Yes, that's rare, and it doesn't necessarily have to happen to you.
There are many other possibilities.

But I just wanted to have it written down.
Before you take drastic actions with uncertain outcomes,
It's often better to address the simpler issues first, in a sequential manner.
And that's also why it's a good idea to occasionally take a look inside the fuel tank.
or to exclude it in any other way.

Another question: The ESP has 3 electrical connections.
a cold start enrichment valve, and a fuel cutoff valve.
and a third one for "?".
Can someone tell me what this part is used for?
(see photo, arrow) is responsible for the side of the espresso machine.
It draws approximately 1.5 amps of continuous current.

Hi there,
It's possible that this is an A/E circuit for the load-dependent start-up control.
Various actuators were introduced with the rise of emissions discussions, before a shift towards EDC (Electronic Direct Control) was considered. However, I can't discern enough details from this information.
I would first ensure the proper function of the low-pressure system before investigating the high-pressure section. The (deaerated) pump must circulate fluid from the suction side to the return side during operation.
You can achieve that with two containers and a vented system.
hg
Herbert.

Hello Herbert,

Regarding the inspection of the low-pressure system, please refer to my question from January 24, 2020.

At the very least, the wing cell pump must be working; that is, diesel fuel should be flowing out of the return line.
hg
Herbert.

The question was actually: How much diesel fuel is needed when "organizing" (presumably referring to a vehicle or engine).
Does it leak out of the return line, either as drips or a stream?

Good morning.
"Beam" is perhaps too strong a word, but a glass should be able to fill itself in approximately 20-30 seconds.
hg
Herbert.