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Thread: Injector pump removal / repair

  
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    Injector pump removal / repair

    Hi all,
    I have a '94 Astravan Merit 1.7td. I've never had it running (only owned it a couple of weeks and been on holiday) And the girl I bought it from said the fuel pump was leaking. I've had a quick look under the bonnet, the front of the engine is wet, especially underneath the injector pump.
    I've currently got the battery out and on charge as its totally flat, the van has been stood for 2 or 3 months! I plan to clean the engine bay with gunk or similar, then try to start her up and watch the injector pump (thats if it'll start).

    Has anyone on here replaced an injector pump on an early 1.7td engine before, if so any advice?

    Also are there different types of injector pump? Just to make sure I don't buy the wrong one as these things ain't cheap!
    Heres a pic of mine in situ:

    Forgive me, I'm new to all this ..... and I'm a bit thick!

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    Hi SeanH,

    Good for you putting up a picture. That looks just like mine. Hopefully after you've done a clean-up and fired it up (assuming it will start up) you will be able to spot the source of the leak. Might be something simple to fix rather than having to replace the injector pump. Fingers crossed.

    Just recently there was a guy on one of these forums that found a diesel leak due to improperly installed washers at the banjo connection to the injector pump. Lots of stories about diesel leakage from leak-off tubes between injectors but maybe that's not your problem.

    Anyway, keep us updated - I'll be interested to hear how it goes...

    Cheers, Paul

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    I was thinking more about your diesel leakage. I reckon its probably is worth checking those diesel-return ("leak-off") tubings - maybe the ones right next to the injector pump are leaking. The tubings material gets old and brittle.

    Cheap and easy to replace - if you buy some pre-cut set, just yank the old ones off and push the new ones into place. I bought about a 1 meter length of the tubing from a local diesel mechanic, cut the required lengths and popped them on...

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    Just spent some time outside trying to hot wire the van (I've lost the keys) to find it's alarmingly easy

    Anyway, I got it started and had a nosey around the fuel pump area, and sure enough, it's spueing diesel out.
    It looks as though it's coming from a join shown in the pic below (pic taken from underneath the engine), is there a gasket kit or something I could get to cure this, or is it a new pump?

    Forgive me, I'm new to all this ..... and I'm a bit thick!

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    Hi again Sean,

    Hey that's great that you got it running - if it runs as is then I would say that the injector pump appears to be capable of doing what it is supposed to do, its just leaking somewhere. Can't see why you would want to replace the entire pump.

    Maybe it is just a failed gasket or something, however there looks to be diesel all over parts around and above the spot indicated - you really need to clean everything up before identifying the source of the leak.

    A couple of years ago I had a trace of leakage where one of those fuel pipes is bolted on in your picture and just tightened the locking bolt thing ever so slightly. But in your case it kind of looks like its coming from above somewhere. Also, I think I remember someone describing a leak from some top gasket once I wonder if your is leaking from up top somewhere and flowing down to the area indicated.

    I reckon you should go buy a spray can of carb cleaner or engine cleaner or whatever. Thoroughly clean and dry the entire pump etc. Start it up and watch closely to see exactly where it is leaking from, then you might have a good idea what needs to be done, parts or seals that you might need.

    If I remember correctly its a Bosch VE injector pump. Serial code should be on a small plate on the front side of the pump. Once you know for sure exactly where it is leaking maybe you could make a couple of calls to diesel specialists and get some info about parts from them. I once contacted "Diesel Bob" in Lancashire - good info on his website.

    Cheers, Paul

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    I just spent some time surfing the net for more info on VE pump and seal kits. Saw a kit for $25 US. Saw some great step by step instruction on complete injection pump rebuilding - interesting but looks rather fiddly.

    Anyway, assuming you can source the seals, there are a couple of the seals that you could replace yourself, like maybe the o-ring at the distributor head in your picture, otherwise might be best to pay a diesel specialist too install them...

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    Cheers Paul,
    I'm going try and drop it off at a garage round the corner, they're not a diesel specialist, but they are a non main dealer Vauxhall specialist. See what they think.
    Forgive me, I'm new to all this ..... and I'm a bit thick!

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    Good idea having them take a look - hopefully it'll be a relatively simple job and it won't break the bank to have them install a seal or two. I downloaded a couple of blow up diagrams of the injector pump and can see a couple of likely faulty seals.

    And hopefully its something they could do with the pump in place. If it does have to be removed that means removing the cambelt - and if the cambelt has to be removed then I guess it would be a good time (cost effective) to replace the cambelt, tensioner and probably the waterpump as well.

    And there's more - if you happen to have a leaky crankshaft main seal and the cambelt is being done then it would also be a good time to have that replaced...I did ask the mechanic who did my cambelt a couple of years ago top replace the seal but he didn't and it has leaked ever since.

    Good luck - let us know what they find at the garage

    Cheers, Paul

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    Could you either post those diagrams up here or maybe send them via email or something?
    I got my Dad to speak to a mate of his that tried to repair his Astras fuel pump, and they said they removed the pump, got it on a bench and started to strip it down. But it was sprung loaded and bits came flying out everywhere. Thats why I've decided to give it to a garage this time. I'll try to do most things myself, but I don't fancing loosing an eye!!!
    Forgive me, I'm new to all this ..... and I'm a bit thick!

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    Sure I'll send you a jpg diagram (Japanese but at least you can see all the seals etc), VE pump rebuild PDF file and links to a couple of websites including the American site with another blow-up diagram and another site with rebuild info and great pictures.

    Cheers, Paul

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