Has Anyone Rebuilt an IP themselves-Can it be done?
 

Just wondering if the Injection Pump can be rebuilt at home? Not that I have one to do. I had one go bad a few years ago and really wondered if it were possible.

Boneheaddoctor claimed he did it.

When you see the bench Gus Pfister of Pacific FI has to tune IPs you get the sense it's not something you do at home. His bench simultaneously measures the flow through each injector line throughout the rpm range. Also has a mode to set the ALDA.

Sixto
93 300SD 3.0 - comatose

No, it's not something that can be done at home. It requires very clean conditions and a test bench to get the all the settings correct.

http://www.worldtst.com/img/TU.jpg

That's not exactly something most mechanics have in their garage.

Ip
 

The main problem is that the special Bosch tools are needed for safe (non-damaging to internals) disassembly and reassy....I watched the Bosch guy here take one apart and the tools are special items....The pressure and flow bench is another item as pictured above...those things are major bucks...
I think they charge over 100 dollars just to hook up an IP for testing.....
The good news is that most of our Bosch inline pumps are ok even with all the miles on them.....A lot of IP's get rebuilt that don't need rebuilding......

It just shows that with the right tools any job is possible...
but not necessarily at home.:(

Unless you have or plan on going through a ton of these cars its not really worth setting yourself up to do this. Serious IP problems are pretty rare so $100 once in a blue moon to get them tested is fine IMHO.

I have been driving MB diesels for a while now and other then messing with the delivery valve seals once I have never had to touch an IP. Well except for timing of course.

Timing, delivery valves, shutoff diaphragm and rack damper are all I've ever had to mess with.

Not at home.....
 

A test/calibration bench is required......there aren't really many "special" Bosch tools required, most of the stuff needed can be had on a Snap-On truck....some special torx bits, and such.....

But, even if you had rebuilt many FIP's over the years.....you still would not want to do it at home.....and you would still need the Test/Calibration bench, I think that a good used one goes for somewhere between $70 and $100 thousand US Dollars.....

SB

The reason someone doesnt chim in here and explain how he has successfully completed a rebuild on one of these is the experience was so troublesome that he is now wearing a straight jacket in a mental institution.My mechanic has a sign on his office door, $80 an hour , $95 an hr if you watch, $115 if you help .Not being a wise a$$ ,he just sets the record straight.How much is a IP rebuild?

My SDL IP didn't need a lot of work but one of the attachments between the positioning rack and a delivery valve plunger (or whatever the proper terms are) was loose. No way I could have solved that at home.

Sixto
93 300SD 3.0 - comatose

Bonehead is just not on this forum anymore. He is not in an institution.

That looks like a modified dairy machine .Man 80 k for that ,no wonder the techs charge so much for an IP rebuild ,their trying to just break even with their investment.

So where do you go? The local Bosch guys say they dont have all the MBz tools. Dont say FInland, I'm not looking to run 10 sec 1/4 miles here!

Is there a rebuilding service folks here have used in the past?

I just bought a rebuilt unit when mine started acting up, probably not the cheapest solution but minimum time and hassle required.

i am wondering if a bench tester can be built relatively cheap. i mean all that i can think it does is makes sure the same volume of fuel is pumped right?

hook an IP up to a motor of some sort that can get up to 5500 rpm have hardlines go into 5 or 6 graduated cylinders. run em and adjust as needed.

You would need some sort of mechanism to gauge the quantity and timings of delivery. I would imagine that large machine would not longer be needed in todays digital world.

You would need some way to drive the sprocket and keep the pump lubricated.

Are flow specs vs rpm and throttle position provided in the manual?

Sixto
93 300SD 3.0 - comatose

pump diesel.. don't know about the manual... i was just thinking on the way to adjusting my valves of a way that it might be able to be done inexpensively.

It's not that simple. These machines count rotations (Pumping action) exactly, fine RPM control, measure delivery volume in cubic millimeters, among other things. They also take quite ALOT of power to run, most of them specify 440volt power to operate. There are plenty of very good reasons why they cost as much as a house. :)

Don't forget, the IP turns the same rate as the cam (1/2 crank speed) so our IP may only see a maximum speed of about 2,750rpm if you take the engine to redline without a load.

Gus Pfister at Pacific Fuel Injection in South San Francisco, CA has a good reputation. Your car will probably be down for 7-10 days since he doesn't have an exchange service.

http://www.bayarea02.com/features/pfister-interview/index.html

Sixto
93 300SD 3.0 - comatose

http://www.boschservice.com/ServiceLocations/ImageMapResults/ImageMapResults.htm?st=NY&typ=DC&cntry=USA

Is D&W the local Bosch shop you contacted?

Pacific FI isn't on the list :eek:

Sixto
93 300SD 3.0 - comatose

That's odd.....
 

I never had a "Certified" Bosch FI shop claim that they did not have the "special" tools required to do any job.....

Don't expect them to remove and reinstall the FIP.....you and/or your mechanic have to do that part.....and you just take the FIP to the shop.....in my experience they will most probably have a rebuilt and calibrated FIP ready to go, and just take your pump in lieu of a core charge.....I realize that these cars are getting older, but the Diesel Shop that I use is no longer Bosch "certified" because of the Bosch requirement to have all of the necessary equipment to service all of their line.....the computerized components on the newer stuff was the issue there.....but they still have a couple of MB FIP's on their shelves.......

SB

You can do the same thing by just calling Phil, he sent me one in the overnight mail and I had my indy install it the next day, no problem.

DIY bench tester
 

Here's a crude DIY IP tester...