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Bosch Injector Pump Overhaul

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Bosch Injector Pump Overhaul

Postby meterreader » Tue Jul 05, 2016 7:37 am

I have a 1996 smiley transit diesel. The Bosch injector pump is leaking (low pressure) from the rear of the pump. I got a seal kit and went to my local mechanic to get it fixed. He said the location of the leak means pulling the pump apart and requires specialised equipment as it has to be bench tested. Is this true or can the seals just be replaced ?
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Re: Bosch Injector Pump Overhaul

Postby vanfox » Fri Jul 08, 2016 11:54 am

viewtopic.php?f=4&t=170503#p1448757 3rd link down?

There's a description of reassembling an IP here, May 10th. May help if you can find the seal position. I guess the IP has to come off the engine. A good engineer should be able to change the seal.
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Re: Bosch Injector Pump Overhaul

Postby meterreader » Fri Jul 15, 2016 10:32 pm

Thanks for the info. The whole thing is beyond my capability. I located a company that will overhaul the pump ( replace all seals ,check and replace worn components etc) for a reasonable price. So I have decided to go that way.I think the bench test and associated expensive test rig is only required if the injector pump pressure has to be calibrated or re set. Thanks again for info
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Re: Bosch Injector Pump Overhaul

Postby meterreader » Thu Apr 12, 2018 9:38 pm

OK now I am in trouble.
The Bosch pump has been overhauled and fuel controllers set back to factory standard. It has been re installed again assumeing that timing has been set to standard. When I picked up the van took it for a test drive and struggled to reach 100km per hour. I blew a radiator hose due to overheating. The van ended up back at the garage. I explained to the mechanic the information gleened from this forum. He agreed to wind up the fuel supply at the pump but said the timing was already advanced. I think he had had enough of the job? The van is currently running well apart from grey smoke from exhaust on start up and a black smoke cloud that James Bond would be proud of when you really put your foot down.No obvious symptoms of damage due to blowing hose.
Where do I start?
Do I check the pump timing and advance further if required.
Do I wind back the fuel supply controls 1/4 turn at a time til it seams ok. I had a bosch injector pump manual on line but cant find it. I believe that there are two adjustments reqd on pump. Which is which?
I have been able to fix so many little problems with my van due to reading this forum and also tips on improvements, keep up the good work.
Also..... the fact that the epic pump is no longer installed can I assume that the "computer" and associated sensors are now obsolete ?
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Re: Bosch Injector Pump Overhaul

Postby Chuggy » Thu Apr 12, 2018 11:20 pm

Some links for online VE pump info here viewtopic.php?f=4&t=184873

basically the screw at the back of the pump does top end black smoke, wind it back a little, screw under cover on top of pump does low range

The bosch IP only has one electrical wire to the stop solenoid, the rest of epic stuff is redundant.
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Re: Bosch Injector Pump Overhaul

Postby meterreader » Fri Apr 13, 2018 2:41 am

Thanks for the info. I will do that now.
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Re: Bosch Injector Pump Overhaul

Postby cherniy_chack » Mon Apr 16, 2018 7:41 pm

Hi,meterreader.
You heve turbo motor with pompe Bosh?
And you heve black smoke?
Can you specify what modes of black smoke?
Maybe you have a problem with the turbocharger.
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Re: Bosch Injector Pump Overhaul

Postby meterreader » Mon Apr 16, 2018 9:38 pm

I foolowed "chuggies" advice and no more black smoke. Just a 1/4 to 1/2 turn on top end screw on injector pump. That is back of pump screw that controls top end fuel as per advice above.
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Re: Bosch Injector Pump Overhaul

Postby VMH » Sun May 06, 2018 12:43 am

How is it running now?
I rebuilt my pump because the cam plate inside had worn out but it took ages of fiddling with the fuel screws and timing to get it running good. With hind sight I should have taken it to get set up on the bench but didn't really have the money.
Now it will cruise nicely at 100kmh but there is a bit of black smoke going up hill which I put down to the injectors being old as I cant get rid of it by turning the fuel down.
Mine is a 1995 lwb high top 190, carrying tools and with the back lined and semi campered.
Also I was running it on the cheap fuel option from the fuel station but recently changed to the fuel with additives because I had noticed how many cars there are around chucking out black smoke, and wondered if it was the cheep fuel. Now it is now running much better but it got better gradually like the fuel was cleaning out the injectors but maybe that is placebo.
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Re: Bosch Injector Pump Overhaul

Postby twin wheel camper » Sun May 06, 2018 9:47 am

VMH wrote:How is it running now?
I rebuilt my pump because the cam plate inside had worn out but it took ages of fiddling with the fuel screws and timing to get it running good. With hind sight I should have taken it to get set up on the bench but didn't really have the money.
Now it will cruise nicely at 100kmh but there is a bit of black smoke going up hill which I put down to the injectors being old as I cant get rid of it by turning the fuel down.
Mine is a 1995 lwb high top 190, carrying tools and with the back lined and semi campered.
Also I was running it on the cheap fuel option from the fuel station but recently changed to the fuel with additives because I had noticed how many cars there are around chucking out black smoke, and wondered if it was the cheep fuel. Now it is now running much better but it got better gradually like the fuel was cleaning out the injectors but maybe that is placebo.



Maybe you already do but try putting it a small measure of 2 stroke oil on with your diesel :idea:
This will help clean you full fuel system out including your injections,it also helps quieting down the Di a little which is worth it own it’s own :lol:
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Re: Bosch Injector Pump Overhaul

Postby kennystag » Wed Sep 19, 2018 4:51 pm

When you say use a little 2 stroke oil in with the diesel, how much to a full tank.
Cheers
Stag
:)
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Re: Bosch Injector Pump Overhaul

Postby INTRANSIT » Wed Sep 19, 2018 8:29 pm

I used to use about a 3rd of a litre (coke can full)
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Re: Bosch Injector Pump Overhaul

Postby INTRANSIT » Wed Sep 19, 2018 8:31 pm

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Re: Bosch Injector Pump Overhaul

Postby cherniy_chack » Mon Sep 24, 2018 2:47 pm

Atmospheric diesel usually smokes black smoke, if the low pressure of opening the injectors.
The serviceable fuel pump and serviceable injectors do not give black smoke.
I used the old pump and nozzles with low opening pressure and I had a lot of black smoke.
When I installed the new injectors, I could not start the motor on the old pump.
I installed a serviceable fuel pump and started the engine.
While the injection pump had factory settings, there was no smoke.
Then I began to twist the different screws and got a good acceleration of the car and a little black smoke during the dispersal.
And then I installed the turbocharger and turbo injection pump and there is no smoke ever.
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