[Vwdiesel] Injection Pump Blues

[E. J. Gilbert]

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[ Picked text/plain from multipart/alternative ]

Hi Gang,

I am asking for some diagnostic assistance. I recently changed out a leakin=
g fuel injection pump with a used pump which had recently been resealed and=
 calibrated.  The engine is running worse than it ever has with low power, =
excessive vibration, and high fuel useage.  The "new" injection pump is noi=
sy.  Perhaps something in my technique is the cause of the problems.  I am =
going to list my actions step by step to see if anyone has an insight into =
the engine problems.

1=2E  Removed the valve cover and top belt guard.

2=2E  Set engine on top dead center with the valves pointing up on the firs=
t cylinder and the cam slot parallel to the head.  Inserted fabricated meta=
l bar in the slot.

3=2E  Removed injector lines, fuel supply and return lines and stop solinoi=
d wire.

4=2E  Loosened the nut holding the cam gear in place

5=2E  Loosened the belt tension device and slipped the toothed belt off of =
the cam gear and the injector pump gear.

6=2E Loosened the nut holding the injector gear in place and removed the in=
jector pump gear.

7=2E  Loosened the nuts holding the injector pump in place and removed the =
injector pump.

8=2E  Installed the new injector pump paying attention to lining up the sea=
m of the injection pump with the groove on the injection pump mount.

9=2E  Installed the injector pump gear and rotated the gear until the slot =
in the tooth almost lined up with the mark on the pump mount. (was slightly=
 to the left of the mark-CCW direction)

10.  Installed a 1/4" drive, 7/16" craftsman socket in the pump locking hol=
e=2E

11. Slipped the timing belt back on the cam gear and the injection pump gea=
r and activated the belt tensioner to hold the belt snug.  Slot in the cam =
gear still a little CCW from mark on mount. Removed locking socket.

12.  Finished tensioning the belt and checked that still on TDC.  Tightened=
 the cam gear.  Slot in cam gear still a little to CCW of timing mark on mo=
unt.

13.  Removed bar holding cam in position.  Installed dial indicator device =
and rotated engine CCW until reading was constant (about 1/4 revolution).  =
Zeroed the dial indicator and rotated engine CW until TDC.  Dial indicator =
was reading about 0.75.  Rotated pump CCW until reading was 0.94.  Tightene=
d pump mounting bolts.  Rotated engine CCW and then CW to verify that the r=
eading was repeatable. Slot in tooth still a little to CCW from timing mark=
 on pump mount.

14.  Filled injector pump with diesel, attached all the lines, covers,etc.

15.  Engine fired up after bleeding.  Idle is smooth, but low on power and =
suddenly increases speed after reaching a certain RPM in first, second, and=
 third gears.  Very slow to drop back to lower RPM's.

Can anyone spot a flaw in the technique used or something else for me to ch=
eck before I condemn the pump?  Any suggestions would be appreciated.

Thanks,

E=2EJ.







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