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  #1  
Old 08-24-2008, 09:04 AM
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Join Date: Sep 2006
Posts: 54
IP Help, 99TD

My 99 TD is a running on 5.
120,000k

I have rebuilt the head.

Compression is 370-380 psi on all cyl.

Injectors have been rebuilt.
No 1 cylinder doesn't fire.
I can unscrew the injector line while running and fuel squirts every where.
I swapped the injectors, no differance.
I read the manual on injector pump. I do not have the tools to get the delivery valve off.

Removing the pump assy requires special tools I don't have.
Is there any way I can test the fuel pump on the car or any suggestions??
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  #2  
Old 08-24-2008, 11:27 AM
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Join Date: May 2007
Posts: 830
Quote:
Originally Posted by oldwheels View Post
My 99 TD is a running on 5.
120,000k

I have rebuilt the head.

Compression is 370-380 psi on all cyl.

Injectors have been rebuilt.
No 1 cylinder doesn't fire.
I can unscrew the injector line while running and fuel squirts every where.
I swapped the injectors, no differance.
I read the manual on injector pump. I do not have the tools to get the delivery valve off.

Removing the pump assy requires special tools I don't have.
Is there any way I can test the fuel pump on the car or any suggestions??
I noticed in your prior posts after removing the head that #1 was wet and sooty at that time, prior to you doing the head work. That would indicate either the injector, or the delivery valve for that cylinder was malfunctioning. Since you interchanged the injector, you eliminated that suspect, which leaves the delivery valve. The socket needed to remove the delivery valve for inspection is about $35-40 and was available on ebay from El paso tools. I have never removed the ip myself, but from what I have read on the forum it is an involved process, and can require special tools to insure success. If I were in your shoes, I would purchase the socket needed to remove the delivery valve and start there. If the delivery valve needs replacement, the parts are available, and they are not expensive. Good luck.
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  #3  
Old 08-24-2008, 12:10 PM
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Join Date: Feb 2004
Location: Walnut Creek, CA & 1,150 miles S of Key West
Posts: 4,874
I believe you have a friend close to you who has the DV socket......

I noticed you have replaced your DV seals and orings previously. Is it possible that at that time the valve element or collar in hole number one were removed? If so, that could change how it meters fuel.

I'd suggest replacing the seals at DV #1 and #2 and VERY carefully comparing the two to see that #1 is installed correctly. Torque is also important. There is some discussion about which torque procedure is correct (30,30,35NM or a straight 35NM only), I used the latter on mine with good results and believe it to be the most current info.

If that does not resolve the issue the pump may need to go to Gus Phister or to a Bosch service center to be recalibrated on the flow bench.
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Terry Allison
N. Calif. & S. of Key West

09' E320 Bluetec 77k
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  #4  
Old 08-24-2008, 12:37 PM
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Join Date: Feb 2004
Location: Walnut Creek, CA & 1,150 miles S of Key West
Posts: 4,874
Question - When you loosen the fuel line from #1 are you doing it at the IP or at the Inj? If at the IP, try the same test at the Inj end and confirm you're getting fuel there too. If not, the line itself could be restricted or blocked.
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N. Calif. & S. of Key West

09' E320 Bluetec 77k
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  #5  
Old 08-24-2008, 03:57 PM
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Join Date: Mar 2002
Location: South Wales U.K.
Posts: 1,064
Quote:
Originally Posted by oldwheels View Post
My 99 TD is a running on 5.
120,000k

I have rebuilt the head.

Compression is 370-380 psi on all cyl.

Injectors have been rebuilt.
No 1 cylinder doesn't fire.
I can unscrew the injector line while running and fuel squirts every where.
I swapped the injectors, no differance.
I read the manual on injector pump. I do not have the tools to get the delivery valve off.

Removing the pump assy requires special tools I don't have.
Is there any way I can test the fuel pump on the car or any suggestions??
Is this vehicle a CDi...?
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Alastair AKA H.C.II South Wales, U.K. based member

W123, 1985 300TD Wagon, 256K,
-Most recent M.B. purchase, Cost-a-plenty, Gulps BioDiesel extravagantly, and I love it like an old dog.

W114, 1975 280E Custard Yellow,
-Great above decks needs chassis welding--Really will do it this year....
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  #6  
Old 08-24-2008, 07:25 PM
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Join Date: Feb 2004
Location: Walnut Creek, CA & 1,150 miles S of Key West
Posts: 4,874
Quote:
Originally Posted by Alastair View Post
Is this vehicle a CDi...?
Not CDI; a 606.962.
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Terry Allison
N. Calif. & S. of Key West

09' E320 Bluetec 77k
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  #7  
Old 08-25-2008, 08:57 AM
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Join Date: Sep 2006
Posts: 54
Yes, NH Doc is send up the socket and some parts. I thought he was out on vacation. I'm glad to have him neaby for excessive mooching.

But let me answer some questions and some historical background.

The delivery vavles seals were redone twice in my ownership. Once aby the dealer in 05 and once by me in 06. It started leaking 12 months after they did the job. I did the upgraded seal and replaced the crush washers. I did a stepped torquing procedure to the 35 nm.
The was all 30k ago.

The head came off because compression check had no 1 cyl at 320 psi and not holding pressure with leak down. All other cyl were happy. Had some pittting on ex valve seats on all cyl.
Now all cylinders hold pressure and range is 10 psi. Test was run on a moderately warm block, no intake manifold.
When I loosen the line it is on the Injector.

Yes, removing the injector pump looks to be a major pain and several special tools for timing. I hope it isn't necessary.
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