Bosch Injector Pump Removal & Refit

[Banshee]

I'm having some major issues getting the truck to run right since removing the Injector Pump and replacing the head seal on it for a Viton one. This was the whole reason I removed it in the first place to re-seal it as the veg had perished the head seal and was weeping from there.

I removed the pump from the truck without making any markings as I didn't think I needed to given the timing marks that were present on the pump gear visible through the front cover of the engine. I thought that would have been enough :nenau

Can someone tell me what the correct procedure here is for removal and refit?

I've cracked all the injectors and it now seems that fuel is coming out of them fine.

The truck will run and revs but it sounds like I've got a very bad bottom end knock and when it returns to idle it hunts BADLY and the engine is literally bouncing around on it's mounts.

I'm at my wits end with it now and just about ready to push it off the drive by hand and wherever it rolls it stays!!! In honestly just can't be bothered with it anymore.

 

[Banshee]

Just to clarify, its NOT fuel starvation as I've bypassed ALL pipework and used a fresh hose straight into a jerry can of pure Diesel

 

[RJL Services]

not 180 degress out is it i would check timing first

 

[bbbmmm55]

Ive been reading about pump swaps recently. Does this apply to you?

"IF the TD27T i stripped the pump off to replace the ETI pump in my truck is anything to go by.... did you have the timing mark on the injector pump gear between the two marks on the drive gear? also i noted when I dismantled the engine at TDC the keyway on the pump gear was also at the top of the shaft."

Its a post from Bud on another forum.

As mentioned above you may be 180 degress out?

 

[Banshee]

not 180 degress out is it i would check timing first

Ive been reading about pump swaps recently. Does this apply to you?

"IF the TD27T i stripped the pump off to replace the ETI pump in my truck is anything to go by.... did you have the timing mark on the injector pump gear between the two marks on the drive gear? also i noted when I dismantled the engine at TDC the keyway on the pump gear was also at the top of the shaft."

Its a post from Bud on another forum.

As mentioned above you may be 180 degress out?

Thanks for the replies guys, how can I prove or disprove that it's 180 degrees out and how could that possibly be if I matched the timing marks up when I refitted?

I did notice that when I spun the engine there were 2 sets of timing marks, a double . . which I couldn't line up and a single . See pics below

 

[Banshee]

The top picture is how I left it.

Also sorry to sound like such a newbie but whats the process for leaving the engine TDC on one of these?

 

[bbbmmm55]

Still learning about this stuff myself but if you look in your manual section Ec319 covers setting TDC with marks on pulley on the compression stroke. Then go to section Em140 which covers timing the fuel pump back up again with compression stroke.

Probably wrong but i think 180 out is when its not on the compression stroke but when valve is opening.

 

[bbbmmm55]

Should of added its the no.1 cylinder your setting at Tdc.

 

[solarman216]

How many marks on the pump gear? I cannot remember but think it should be 1 which if so would end up between the two on the drive gear, but your description of running is one tooth out, Rick

 

[bbbmmm55]

Looking at the diagram it should be a single z between the double z. The sigle dot is for the camshaft or crankshaft gear.

 

[bbbmmm55]

Well listen to that man. He know far more then I probably ever will.

 

[Banshee]

How many marks on the pump gear? I cannot remember but think it should be 1 which if so would end up between the two on the drive gear, but your description of running is one tooth out, Rick

Looking at the diagram it should be a single z between the double z. The sigle dot is for the camshaft or crankshaft gear.

Thanks all

I decided all off again last night and mustered up the energy required to go outside and get stuck in.

I got to the point of 1 more nut left on the pump and I can pull it back off.

Can anyone confirm if the timing mark is a dot or a Z on the drive gear on a later Bosch variety?

I'm very lucky in the fact that I have not 1 but 2 spare pumps should I have foobared mine after a rebuild but will be surprised if it is that as I followedba great guide that Barrbeast sent me picture by picture.

I'll likely try the one from the 05 breaker next as it's closest era wise to Terrance, this worries me doubly though as I know I haven't upset the NATS currently as it starts.

 

[bbbmmm55]

If you go to makeitfits engine rebuild thread. Post #190 you can see a picture showing his pump gear with the double z but his idler gear has the single z. I think his is a Zexel engine but must be the same? I know theres differences between the two variant but how far im not sure.

 

[Banshee]

If you go to makeitfits engine rebuild thread. Post #190 you can see a picture showing his pump gear with the double z but his idler gear has the single z. I think his is a Zexel engine but must be the same? I know theres differences between the two variant but how far im not sure.

This one is the million dollar question at the moment.

I'll soon find out when I'm home,I'll check my 05 scrapper and Terrance

 

[bbbmmm55]

Feign sickness so you can go home early surely this counts as an emergency.

 

[Banshee]

Feign sickness so you can go home early surely this counts as an emergency.

That's made my day [emoji38]

Just got home and getting changed, let's see if I can get this sorted hey!!!!

 

[jims-terrano]

Good luck Banshee, you’ll get the old girl running again.

 

[johnb5177]

Good luck Zac, you will crack it, patience, grasshopper.......:thumb2

 

[panelbeater]

take the timing front cover off and alighn all the timing marks up thats how i changed my pump from dick and left the pump gear in situe then lined up woodruf key to pump pully and had no problem starting once fuel came through.bolt up in this possion.
key to top.both no1 valves closed for compression stroke.

 

[Banshee]

Just to let everyone know I'm all sorted :thumb2

Elty sent me a whatsapp picture of his new engine which had timing marks on the crankshaft pulley :thumb2

I wound the engine round to there and low and behold there was a single "Z" timing mark on the drive gear as we've seen with Elty and Pete's pics.

It's running a dream now and doesn't sound as knocky as before so hopefully i've solved it. I was relieved when I put t all back together AGAIN and it went first time :bow So I'm still on my original pump which has been rebuilt with a Viton head seal :thumb2 180,000 miles and abused on veg and now it's got a new lease of life again.

The next thing to check is to see if I can clear all of the old stored EML codes and see if the dreaded 21 goes away for good