Bosch Diesel Injection Pump Disassembly

Post by **KennyW** » 24 Nov 2009, 01:54

Thanks for the reply Mike,

I remove the pump weather permitting Thursday and start striping it done as per your and Jim's excellent blog.

I will also take a series of photo's as I progress as each pump we have is slightly different in some way.

Kenny.

Post by **KennyW** » 26 Nov 2009, 23:24

Well,that's the easy part done. The pump is off.

Im'getting quite good at this

I will start to strip same tomorrow.

Question for Mike and Jim.

Is it worth look at the diaphram in the UFO for a rupture

Kenny

MikeT · Post by **MikeT** » 27 Nov 2009, 15:18

Hi Kenny,

I would say yes, it's only four bolts and although I doubt you'll find any deterioration (it's very thick rubber) you might find other issues as I did with the Peugeot pump (boost side full of engine oil for instance).

Besides, you can familiarise yourself with the tuning options inside - it's all good learning.

A word of warning, if you find it's resisting coming out, try rotating while gently pulling as no doubt the metering pin is catching and could bend/break with enough force.

Post by **KennyW** » 27 Nov 2009, 23:15

Hi Mike,

I've start the strip of the pump and basically have in three sections.

1. The upper body including UFO
2. Lower body with distributor shaft
3. Distributor Head.

Plan of action tomorrow is to look at the compoments of each part and try and identify the problem with my pump.

There was plenty of fuel in the unit and fuel at the return so Jim's suggestion that it might be the lift pump is a possibility.

Here are selection of photo's from tonight. I have found 1 problem there is a spring on the fast idle lever was has come loose.

Do you or Jim know which way it fits.

Kenny

Post by **CitroJim** » 28 Nov 2009, 09:41

Hi Kenny,

Good work so far

I "repaired" the last image that was not displaying properly.

Do you mean the coil spring around the fast idle lever shaft? If so, that one often breaks (looses an end) and i should be able to provide you with a spare and a little drawing of how it fits.

A rupture in the UFO diaphragm should just cause a loss of boost fuelling and should not materially affect starting or running. One good way to check for a split is to look at the underside. If it is clean then it is OK.

Dismantle a bit further to get to the lift pump and do also check the pressure relief valve. Blow all the passages with an airline if at all possible.

Post by **KennyW** » 28 Nov 2009, 23:04

Hi Mike and Jim,

Just about finish the strip but for the following triangular nut which I can't find a way to remove, Any suggestions.

I can't see any obvious problem with the pump.

Kenny.

MikeT · Post by **MikeT** » 29 Nov 2009, 14:13

KennyW wrote:Hi Mike and Jim,

Just about finish the strip but for the following triangular nut which I can't find a way to remove, Any suggestions.

They had me stumped for a while but found a split pin opened up and inserted into a deep socket does the trick

Ditto for the pressure regulator valve if you can't get an open-ended spanner on it.

Post by **KennyW** » 29 Nov 2009, 19:53

Thanks for the reply Mike,

How did you place the split pin in the socket

I have just looked at a rebuild of Ve pump on the VWdiesel.com site.

Fantastic $\:D/$

I'll use that to help me as it goes into it with fine details and great photo's.

But I have 1 question what would you suggest to clean the pump after its stripped

Kenny

Post by **KennyW** » 29 Nov 2009, 22:53

Mike and Jim,

I have managed to remove the 2 offending triangular screws, by gentle use of a cold chisel and rubber mallet

Pump now completely stripped.

Now I need to purchase the bosch repair kit.

I am going to photo and record my rebuild and if you are happy Mike, I will add it to your blog for future reference.

Kenny

MikeT · Post by **MikeT** » 30 Nov 2009, 14:54

Hi Kenny, I'm surprised you couldn't use the split pin method but whatever works for you gets the job done, eh?

Adding your rebuild to this thread is most welcome as it'll then include both Peugeot and Citroen pumps.

Post by **KennyW** » 02 Dec 2009, 23:29

Hi Mike and Jim,

Here is the rebuild of my pump which is a Bosch VP20 AC3

Pump No 0 460 494 455 A side view of my pump minus body armour and a rear view of pump with partially fitted body armour. The armour which fits over solenoid is NOT fitted.

Here is the lower half as a shell

Here is the eccentric ring

It must be fitted correct way up or the thread holes will not line up

Here is the inner ring with shims, it is important to fit the shims in the correct way ie the rounded surface to the outside.

Here is the vane plate which can only be fitted one way

Here is the drive shaft fitted with the governor drive, rubber shims (in black), woodruff key and large washer

Here is the driver shaft in position but when fitting remember to locate the woodruff key into the small hole in the inner ring on the eccentirc plate

The next stage is to fit the roller plate onto the drive shaft

The guide pin must be fitted into the timing device which is a spring loaded piston with a bucket which the guide pin slips into. It is case of moving the bucket very slightly back and forward or rotating it slightly left or right until pin slides into the hole.

Unfortunately I forgot to photograph it and can only describe it as follows;
It is cylinder shaped with a hole for the bucket to fit in which also has hole at 90 degrees for the guide pin to go in. This loaded by a spring at one side.

Once in place it is held by apin which goes through the hole you can see in the photo and it is cover by a clip as per the next photo.

The next stage is to fit the dog cog with its 4 legs onot the drive shaft 2 legs inside the roller plate.

Here it is fitted over the 2 legs on the drive shaft. The 4 legged cog has an inner collar which the spring fits onto make sure it is facing you when you look into the pump body.
You can also see the clip over the pin on the guide pin.

Next is to fit the rollers

It is very important to note the rollers have convex washers which MUST be facing outwards when placed onto the roller plate.

Next is the spring which fits in the centre.

The camplate is next and there is only one of fitting this, the legs go onto the drive shaft and the plate with the small head faces the distributor.

Finally fit the govneror lever assembly with the triangular nuts.

To fit the distributor head back onto the pump which has been described in detail in Jim's blog and here on Mikes.

I did the above refit with the pump held vertical which made life alot easier.

Here is a brief description of what I did:

I partially fitted the distributer plunger, link element, control collar and springs together and held the springs in place with vaseline. I held the govneror lever mechanism in place with a small screwdriver so the ball on the lever was in the control collar hole.

The small springs and the 2 guide pins were also held with vaseline.

It was then a case of placing head iinto position and screwing the 4 hex screws down and the bottom half of the pump was complete.

The refitting of the top half is exactly the same as Jim's blog and thereafter it is fitting all the ancillaries to the pump.

Any comments welcome.

Kenny

Post by **KennyW** » 07 Dec 2009, 16:26

Hi Mike, Jim and the rest of the forum,

I have now got pic's of the timing device fitted to my pump and where to put them

I hope this clarifies a few things.
One thing that's worth remembering, the camplates are different on between peugeot and citroen depending on model.

Kenny

MikeT · Post by **MikeT** » 07 Dec 2009, 17:27

Nice going Kenny! Just one observation - did your timing piston not have shims?

Yes, the camplates and many other parts can be different, dependant on application, which gives the hardcore tuner even more options.

Hopefully, yours will work for you now after all that - just a shame you didn't identify the actual fault but at least you've eliminated a great deal.

MikeT · Post by **MikeT** » 15 Dec 2009, 15:42

How's it going Kenny?

Post by **KennyW** » 19 Dec 2009, 22:22

Hi Mike,

I have not completed the fitting of the rest of the electrics as the weather has postponed same

I want to carry out a static timing of my pump prior to fitting it all together.

Hopefully that will be soon.

Kenny