Thread: injector pump leaking 300TDI

Hi Peter, thanks to your advice I purchased a reconditioned Injector Pump from Land vehicle spares and I fitted it about 3 weeks ago. I found that it was not performing as well as my old one, but I suspect that the old one had been tuned. First thing I did was fit a guage for the EGT and spin the fuel pin around so that the widest "step" was facing the front*. That made it quite a bit better. I then screwed the fuel screw in about an eight of a turn. After driving it hard up a couple of long hills I only managed to get to 600 degrees, which is considered a reasonably mild tune (from what I read, around 700 degrees is the suggested top temp).

I have yet to adjust the vacuum compensation (so that the fuel pin opens a little sooner). I will start on that one soon.

* note that I have the Allisport intercooler and this is suggested for them by Allisport. Others may have a view on the fuel pin adjustment to suit the standard intercooler???


Cheers,
Tom.

The reason I am replacing the injector pump is because I detected wet metallic material in the fuel cut off switch area indicating that there is some bad wear taking place in the pump. I have done nearly 4000ks since I first noticed this and although the motor is not giving any signs complaint I am wondering what damage I may do if I keep going. I have the exchange pump but short of time and help to fit as well as tuning it, and really need to do one more trip of about 1000ks before I can do the job. Apart from the pump failing altogether is the a risk of major damage to the motor? Peter

I put up with mine for a long time. 200 tdi. I made a special spanner and carried a small magnet on a stick. When it wouldnt start, out with the solenoid, in with the magnet, out with the metal shavings, back in with the solenoid and away. Could do it in under a couple of minuits but got sick of it and fitted a reco pump( more expensive than yours) Did not seem to do any harm.
Keith

Originally Posted by pjlhat

The reason I am replacing the injector pump is because I detected wet metallic material in the fuel cut off switch area indicating that there is some bad wear taking place in the pump. I have done nearly 4000ks since I first noticed this and although the motor is not giving any signs complaint I am wondering what damage I may do if I keep going. I have the exchange pump but short of time and help to fit as well as tuning it, and really need to do one more trip of about 1000ks before I can do the job. Apart from the pump failing altogether is the a risk of major damage to the motor? Peter

there is a very slight risk that the pump might seize and take out the timing belt with the associated damage that causes.


Id put money on you being ok engine wise but possibly having to deal with the issues from the shavings causing rough running, poor economy and in the extreme leaving you stranded if the plunger looses its sealing integrity. (it takes a while and is a gradual degrade, its not normally instantaneous.)

A temporary, although crude, fix is to put some engine oil or gear oil into the tank to thicken up the fuel mix, some of it will adhere to the plunger and give a little more life but you're pushing your luck when you get to that stage.

Originally Posted by BathurstTom

Hi Peter, thanks to your advice I purchased a reconditioned Injector Pump from Land vehicle spares and I fitted it about 3 weeks ago. I found that it was not performing as well as my old one, but I suspect that the old one had been tuned. First thing I did was fit a guage for the EGT and spin the fuel pin around so that the widest "step" was facing the front*. That made it quite a bit better. I then screwed the fuel screw in about an eight of a turn. After driving it hard up a couple of long hills I only managed to get to 600 degrees, which is considered a reasonably mild tune (from what I read, around 700 degrees is the suggested top temp).

I have yet to adjust the vacuum compensation (so that the fuel pin opens a little sooner). I will start on that one soon.

* note that I have the Allisport intercooler and this is suggested for them by Allisport. Others may have a view on the fuel pin adjustment to suit the standard intercooler???

Hi Tom,

Have a squiz at the notes attached below. The same tuning method can be applied to the standard engine or one with upgraded intercooler, increased boost etc. Since writing these notes I've fitted an upgraded intercooler and upped the boost to about 20 psig, sensed at the manifold. (I'll get onto Rev.3 any year now...) There's plenty of range of adjustment in the pump.

The leak on my pump appears to be coming from the small screw on the back of the distributor housing between the bottom two delivery connections I am unable to find what that screw is for

Originally Posted by Chris Commins

The leak on my pump appears to be coming from the small screw on the back of the distributor housing between the bottom two delivery connections I am unable to find what that screw is for

There should be the 4 allen head screws around the outside, the 4 injector pipe fittings and 1 bolt head in the middle.
The bolt head in the middle might be what you are reffering to. It is an access port for measuring the lift. It is sealed with a copper washer and can be removed easily as it is just a plug.