Zd30 Zexel VP44 Replacement Due To Non Start

[Dcd87]

Hey everyone. Moved my thread with the issues I have been having into here, rather than staying on my introduction.

Bought a 2003 3.0tdi 2 weeks ago and it died on me doing 70mph on a dual carriageway. It failed to start and I ended up being recovered home.

Carried out all the diagnostics from the manual and a Bosch VP44 manual and basically proved the pump to be dead. Looked like the pump ecu had packed in.

Ordered a “refurbished” (using this term loosely) pump which I fitted after the chew on removing the old unit. Turned out to be no good and I couldn’t get it to generate high pressure.

Stripped it out and currently have a dead car sat on my drive, much to my frustration, but worse is that I have been scolded off swmbo.

I have kicked off with the company I bought the pump off and am having another unit sent to me. In the mean time I found a company that can repair the ECU in Workington. Stripped the ecu off my original pump and sent it to them. They found a transistor burnt out and separated from the PCB. The repair for this cost around £50 and I should have ecu back tomorrow. Sat afternoon is looking likely for the repair so fingers crossed for then.

If it works, it’s cost me around £80-90 in parts including fuel filter and new fuel lines. The two pumps are being sent back for a refund of the £690 the “refurbished” unit cost.

Hopefully this will get the Terrano 2 back on the road and ready to see me through the rest of this shooting season and beyond. I had plans for the truck with some light mods to make it a useable work horse.

See some of the photos of the current state of the car on my drive, and my bonus facebook find of four insa turbo rangers for my wheels.

 

[Dcd87]

Poorly car

 

[Dcd87]

Engine stripped and pump out

 

[Dcd87]

Bargain find. £60 for four insa turbo rangers with decent tread.

 

[solarman216]

Are, you sure the replacement pump was US? as I think the pump ECU needs to be "paired" with the main ECU, the fact you original has been repaired is a better bet as the two should "talk" to each other, better, Rick

 

[Dcd87]

Are, you sure the replacement pump was US? as I think the pump ECU needs to be "paired" with the main ECU, the fact you original has been repaired is a better bet as the two should "talk" to each other, better, Rick

I have bee round and around with this now and i think its right. i have some documents that say it needs, pairing and others that say they don't. So i'm not entirely sure anymore!

The ecu arrived today so hopefully get it fitted tomorrow.

 

[Dcd87]

Fixed it and its a LOT cheaper than a new pump!

So after ripping my pump out and the "refurbished" one not working, i sent my ECU off for repair.

The company found a transistor failed and separated from the PCB. They have replaced it with a new part and rebuilt the ECU.

From shipping the ECU to it being returned was 5 working days.

I refitted the ECU to my original pump which was mechanically good. Primed the system and cranked it over. It took a few attempts then i got a splutter. A few more cranks and it fired up much to my elation.

In total the repair of the ECU cost me £40.95 and i have been refunded the £690 for the spare pump which was no good.

I have put the Hyperlink below for the ECU repair ad from Ebay.

https://www.ebay.co.uk/itm/133442223233

 

[solarman216]

That is really good news, that there are still firms out there that are willing to repair rather than replace, from my recently gained knowledge of the VP pump I can quite happily state that veg is a no no, but also that as above the pump ECU can be removed and be repaired but it will only work with the original on car main ECU, another pump not recognised by NATS will not work until NATS has been reprogrammed, expensive, Rick

 

[Banshee]

That is really good news, that there are still firms out there that are willing to repair rather than replace, from my recently gained knowledge of the VP pump I can quite happily state that veg is a no no, but also that as above the pump ECU can be removed and be repaired but it will only work with the original on car main ECU, another pump not recognised by NATS will not work until NATS has been reprogrammed, expensive, Rick

I was hoping that his spare pump was good as I wanted to know if it indeed caused a NATS lockout. I wonder if the fact that it wasn't generating high pressure was down to NATS in any way shape or form......

I wonder what putting the trucks original ECU on the spare pump would have behaved like :nenau

 

[Fez_uk]

but it will only work with the original on car main ECU, another pump not recognised by NATS will not work until NATS has been reprogrammed, expensive, Rick

But sending it to places linked there's probably ways around it. I know there is with VW caddy, Maybe it's a less complicated system :augie

 

[panelbeater]

glad you got it sorted,being a 3l owner.

 

[Dcd87]

glad you got it sorted,being a 3l owner.

Im over the moon as its getting used as my daily now.

 

[RobN]

Thanks, added to my useful 3.0 info.

 

[panelbeater]

rick,getting pcb repaired is a dying trade,when i had my workshop i purchased a mig when they became affordable to the smaller workshop,it was still a lot of money though,cant remember the make but it was a good one.as things do it became faulty out of gtee.the nearest agent was about 12mls away so went there to see about getting it repaired,common fault they said and that it will be 80 for exchange pcb.
i said no and came away to look for a chap i new might be able to help,found him,gave him the pcb and got it back a couple of days later,fitted it and all good.cost 5p yes 5p for the blown item.need less to say well happy.

 

[solarman216]

You are quite correct, I often repair small not too complicated boards, but getting them done commercially is a virtual no no, I have an inverter here that no one will even look at, nothing obvious to be seen but it overloads as soon as it is connected to a battery, I would bin it but it is 2k £ worth, so yes he did very well to get it fixed, Rick

 

[Fez_uk]

You are quite correct, I often repair small not too complicated boards, but getting them done commercially is a virtual no no, I have an inverter here that no one will even look at, nothing obvious to be seen but it overloads as soon as it is connected to a battery, I would bin it but it is 2k £ worth, so yes he did very well to get it fixed, Rick

I fixed my boss's inverter for his solar, It was a common issue for them which was documented online. Burnt out relays If I recall correctly.

If the fault could easily be seen (burnt out, swollen capacitors etc), If the part that's damaged is obvious I have to skills to replace it, but not the skills to troubleshoot what the problem part is if no signs of damage.

 

[Banshee]

I've been doing a lot of reading into the 3.0 VP44 (PSG5) failures recently thanks to this thread as I wanted to be clued up should I ever buy one that fails or anyone else needs help.

I'll be honest, after some reading and some swatting over diagrams of the VP44, I'm seriously off put and think I'll deffo be staying in the TD27 domain for a while yet.

It seems the pump relies on a constant flow of fuel to keep the temperature of the ECU on top of the pump in check. 80% of the failure with this pump are supposedly due to overheating, there's a transistor inside the pump that gets to hot and burns out that has to be replaced.

It should be replaced with an "IRLR3110Z" for the Terrano but the repair job is certainly not one I would attempt even with my improved soldering skills of late repairing the pile of CB radio mics and CB's that I've acquired over the summer from the car boots.

The ECU for some reason has also been coated in a clear resin type liquid that sets clear and hard and has to be tactically removed before a repair can take place, I've seen 5-6 videos of the same repair done on VP44 pumps on YouTube and I've not seen a solder job that I approve of yet.

As of yet, I've not been able to find a DIY at home way of re-coding another VP44 ECU with your Terrano in the eventuality of a full pump swap, from what I've read, I'm guessing that this is why the OP was unable to get high pressure from the replacement pump that he purchased.

Here's what you're working with;



And here's a very useful thread that I found;
https://www.digital-kaos.co.uk/foru...osch-VP30-VP44-injection-pump-repair-solution

 

[Banshee]

Some videos of others "attempting" a repair.

I would love to know how long each one lasted;

https://www.youtube.com/watch?v=z1JLpM9fqVQ&t=925s

https://www.youtube.com/watch?v=133qU9sMatA&t=332s

https://www.youtube.com/watch?v=ydwzUSeH-4A

 

[RobN]

Awfull

Those videos are beyond bad:doh

Modern electronics are pretty sturdy and are relatively well protected from static and temperature shock. I do not recommend going all out with wristbands and static protection bays but treat them with some respect. Static and thermal shock is no longer the death sentence to components it was in my youth but it will lessen the component life considerably.

 

[solarman216]

OK when I first saw the post about the cheap repair (MOSFET Transistor replacement) I thought it was a very lucky find, but now I know different, it seems this pump is renowned for this particular failure on a very big scale, plus to a lesser extent there are issues with poorly de burred high pressure plunger machining which leads to complete pump failure, (this is mainly prior 2000 pumps) I will be sourcing a complete pump ECU as a hands on spare for my wife's 3, cheap at around £40, they can be had UNLOCKED so the car ECU will talk to it, Rick