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Discussion Starter #1 (Edited)
Hi all,

Ok i decided to put this here because A it is in the DI relivant section and B i think it might help some noobs sitting on the fence who just jump straight in to this section like i know a lot of us do here to read about the DI patrol! And hopefully here on this thread i can help show how to do an Injection pump change yourselfs in detail which i plan to do & i will try to carefully detail it as good as i can & if the feedback is positive etc i will continue here with it;) I have removed an IP recently from my other 2001 Patrol (I got for breaking) but i didn't go in to much detail, however that is in on my other thread too found in user menu.

Anyway to get to the point here! .....So i have picked up a real mint Black 2007 new shape seven seater Patrol with very low miles (120K's) the thing is mint with full leather heated seats (Black) front and back, it has elec sunroof and 4x NEW BFG tires.It has every extra! :) i have been lucky in recent times with my finds and lucky too to come across them at the right time because they don't hang around for too long. In all honesty i was waiting for one like this to come up that i could work on myself to repair because it is too good not to.Anyway about the machine in question-- All the chassis has been fully undersealed and everything was carefully maintained by the previous owner,he has receipts for a hell of a lot of chassis parts inc full hub rebuilds with bearings and seals etc to mention only a few, comes with two keys,everthing works as it should. We gave it a good going over and i can't fault body or chassis and the engine is turning over nicely.These are getting rare nowadays here and very hard to come by in this body shape as lads hold on to them and it's mostly the older shapes that come up.This is the first one of these i have seen coming up in a long time. The guy wasn't planing to sell but i contacted him.

Long story short i spotted it at my local mechanics and i was quickly bought up to speed on the machine,the Injection pump failed and the owner bought a used pump to try but it was for an Auto (This is manual) and they had some issues with that.... so he got YES another used pump (Big mistake) but i know now he got caught the second time with a bad faulty pump again because both times he didn't pay too much for the pumps and took a complete chance... & that is a mistake i made myself in the past too at least with one pump and that was enough LOL! So as time went on he was stuck for the cash as he bought a van for work in the meantime not been able to get this going and it looks like i pounced on it at the right time ;) He was fed up and decided not to spend any more loot on it....shame i think as they are making big bucks here with seats in the back...this one is a crew cab so i get cheap tax here on it with my business.I seen the Patrol around locally and knew it was running sweet prior to the pump going.

I currently drive my 2004 fully rebuilt Patrol which recently had a rebuilt engine and pump, i also recently learned a lot by 'Breaking' another 2001 Patrol i bought last year and that 01 model i was lucky as it had i was told a good pump and i removed the IP (ZEXEL) which i now plan to fit to this new Patrol here myself ;) best thing i done to break the 01 model to learn so much more about Patrols!!

So now i have three Patrols LOL..currently only one driving :p and i look forward to seeing how i get on with removing this pump and refitting it.
My only problem is i have no way of testing my own pump out of the 2001 Patrol that i plan to implant on this new troll , i am only going by word of the previous owner that said it ran fine before Patrol cracked it's head and the compression leaked so bad it wouldn't even kick...in my other thread i documented all this tear down of the 2001 model and the head gasket was damaged very bad so i can believe what he said. (See my other threads in my user menu) i can pay 180euros and a long drive to bench test it i am not sure yet which avenue i will go down with it but i will have a think about it.

So here are some pics of her,i can't wait to get started on this project :) It's been delivered to me tomorrow evening and i'm like an excited kid & i really just love it!!

Truthfully it would be very hard to come out of my own 04 (grey) Patrol now as it's driving so so well....But it too needs work done with bad brakes now and a set of engine mounts and slight body rust over the steps just to mention some....in all honesty i really love the newer body shape though and was tempted to remove my own engine and new pump and put them in this one BUT...i am going to stay cool and keep my own on the road as i need it for work and continue with this project for now because having my own off the road in the meantime would spell disaster for my business! So i will update soon here with the progress! :)
  • :p
 

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Discussion Starter #2
Ok just another quick update,so the deal is done and dusted and now the Patrol is mine :D:eek: So my tow truck is bringing the old girl home to me tomorrow morning.

However excited i am it's still going to be a huge undertaking for me and it's not going to be back on the road overnight.. i am taking the owner on his word and as i said i have seen this Patrol around driving recently but we never know just how mechanically sound a vehicle is until we drive it....so that's the other side of the coin. How ever i have like i said three Patrols now so parts won't be an issue for me :) that's one positive thing i guess.

I suspect once a good pump is fitted it should be 100percent. The owner told me he never had any issue and i spoke to the mechanic who used service it and he confirmed it too and he is a good buddy of mine also.
Like i say though this is going to be a big project for me to get this running...i have removed a pump from my 01 model but never fitted one and set up the timing and all that so here we go!! I have a feeling i'm in for a lot of grief fitting this pump :ROFLMAO:
 

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GUII ZD30DI Wgn
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Ok just another quick update,so the deal is done and dusted and now the Patrol is mine :D:eek: So my tow truck is bringing the old girl home to me tomorrow morning.

However excited i am it's still going to be a huge undertaking for me and it's not going to be back on the road overnight.. i am taking the owner on his word and as i said i have seen this Patrol around driving recently but we never know just how mechanically sound a vehicle is until we drive it....so that's the other side of the coin. How ever i have like i said three Patrols now so parts won't be an issue for me :) that's one positive thing i guess.

I suspect once a good pump is fitted it should be 100percent. The owner told me he never had any issue and i spoke to the mechanic who used service it and he confirmed it too and he is a good buddy of mine also.
Like i say though this is going to be a big project for me to get this running...i have removed a pump from my 01 model but never fitted one and set up the timing and all that so here we go!! I have a feeling i'm in for a lot of grief fitting this pump :ROFLMAO:
I have written up timing and fitting in situ in my build thread after doing mine recently, If you haven't already, download the workshop manual from post #9 of the DI archives.
 

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Discussion Starter #4 (Edited)
Thanks Ross,

As mentioned i have removed the IP from my 01 model but that was easyish because i was tearing the whole thing down anyway,well i still had head and intake manifold on when i took it off and it still was awkward! It's timing this all up and especially around that scissor gear that worries me.... your thread will sure be a help to read over it even though i have studied the timing marks on my 01 model a good bit too which should help.
The only thing i have going for me is there will be no hurry with this so i can take my time not to stuff it up.

Any link GU2?


Ohh and by the way i have met a hurdle already lol... to check and test a pump two diesel specialists i have spoke to need the pump dropped and left to them to bench test it...i was told by both places that it would need to be left for a few days due to the obvious thing them just been busy and it been taken in and tested when they can get a chance.
Anyway, at the risk of sounding distrustful or bad but how does one know that they are going to be 100percent trust worthy here in this situation... it's easy to phone someone back and say Yes your pump needs a 1200euro rebuild because they simply think the pump could do with it anyway even if it bench tests ok😂 I only say this because i thought i could arrive some morning and was hoping to be part of the bench test process or at least be left observe it.... i am paying for it after all!! One specialist crowd quoted me 180euros and the other 50euros but both won't let me wait on the day for the pump.....
Bummer.... now what to do!
So it looks like i have to take them at there word for the bench test process or just fit the pump and see what happens!
Another issue i have with that is the VP44 pumps are rare enough and good ones that go in how do we really ever know what we get back.
I know i'm been pesimistic sounding here but it's easy hand someone back a dudd pump to replace a good one that was sent in and tell them they need a full rebuild....
In some places i have read terrible and scary online reviews recently and this includes even Baileys diesel.
 

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Discussion Starter #5
Well the Patrol arrived and the first step was to take out battery and get it on an overnight charge! You can see the Zexel pump in the background that i plan to fit :) i just had the banjo bolts off and must put them back on and cap everything for the meantime in case dust gets in.
I also removed the top module (PSG) cover and everything looks mint...the solder is 100percent and clean with no burnt look like so often happens when that fails. It's normally the top corner that goes the solder breaks away.
If anyone would like a few shots of that module i can take a few!
 

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Thanks Ross,

As mentioned i have removed the IP from my 01 model but that was easyish because i was tearing the whole thing down anyway,well i still had head and intake manifold on when i took it off and it still was awkward! It's timing this all up and especially around that scissor gear that worries me.... your thread will sure be a help to read over it even though i have studied the timing marks on my 01 model a good bit too which should help.
The only thing i have going for me is there will be no hurry with this so i can take my time not to stuff it up.

Any link GU2?
For link look in my signature, index first post. For Workshop manual, post #9 DI Archives. Mate I would not believe a word from Bailey's, I joined there forum a few years ago to get a few ideas, lasted about a month. When I finally did the job I did it through Diesel Central in Queensland, I had visited them (600k away) and had a long chat, got to know Shawn reasonably well have email contact with him, I have a great deal of confidence in him/them. Just to highlight, Zexel/Bosch parts are interchangeable for the VP44, often Bosch parts are ordered and they arrive in a Zexel carton and vice versa.
 

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Discussion Starter #7 (Edited)
Well i will tell you something about Baileys, they have a video on you-tube advertising 'Blueprinted' pumps and the part that caught my attention was the Brand new housing they give you with every new VP44.... long story short was before i had my own IP rebuilt i actually contacted them and guess what reply i got back, they said i would need to send my own pump in to see what was wrong with it and they would be using and rebuilding my own pump.
What a load of BS!! What about the key part that caught my attention 'The housing'

Look i'm not been bad here or cutting down anyone or any business and i am sure that in the hands of a diesel specialist i have no doubt that we get VP44 pumps handed back that will work faultlessly for many k's to come but i don't believe many if any rebuilt VP44 comes with new housings. I was even told exactly what is done.... new electronics kit this has all the main sensors of the pump on it anyway that plug straight in when the new module is fitted,then depending on condition maybe new timer piston and vane ring and new seals. The rest of the pump is all stripped down and cleaned and inspected. To be fair it's very seldom anything else is changed. And i have yet to see any rebuilt VP44 Pump with a new housing! I got my pump rebuilt recently and they told me it had a new housing well if it did why does it not look like new LOL

End of the day i will pay my money to get this Zexel pump here tested but i don't trust them if i can't see it been bench tested!!! I mean why can't they let me wait....Number one they are not very far from me (two hours drive at best) number two they want me to post it which is going to cost quite a bit....i can't see why i can't be present on the day of the bench test.It is there own fault for this distrust.. this is putting me out having to post this.
If this pump is sent to be bench tested i can guarantee i am in for a full rebuild.

This 2001 model Patrol it came out of wasn't even kicking or trying to fire, i was told that the head cracked and that the pump was fine, the patrol only had 100,000K;s up.... which is low... i know they fail at any K's but what are the chances of a pump going the same time as the head??

When i pulled the head i did see the gasket between 3 & 4 cylinders at the back was really really bad.... the cylinders were full of coolant which told me that even if this pump was good there was no way it was even going to kick!!


Havn't had much other time to look around the 2007 patrol i just got apart from spotting the front discs are very badly worn and will need a change, the heated seats don't work (could be a fuse) and other than that i just need to make a decision now about the pump.

It's a lot of work here without a bench test but i'm tempted to just try this pump!!


See the few pics here of the gasket and head i pulled from the 2001 wine model! Also see that the head itself wasn't too bad looking!
 

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Well i will tell you something about Baileys, they have a video on you-tube advertising 'Blueprinted' pumps and the part that caught my attention was the Brand new housing they give you with every new VP44.... long story short was before i had my own IP rebuilt i actually contacted them and guess what reply i got back, they said i would need to send my own pump in to see what was wrong with it and they would be using and rebuilding my own pump.
What a load of BS!!

Look i'm not been bad here or cutting down anyone or any business and i am sure that even in the hands of a diesel specialist i have no doubut that we get VP44 pumps handed back that will work faultlessly for many k's to come but i don't believe many if any rebuilt VP44 comes with new housings.
As said I spent time talking to them and wasn't impressed, following my personal contact with Diesel Central I paid my money plus a deposit, they sent me a pump, I removed mine and after installing new pump I sent old one back and they returned deposit (I had already purchased the+50% injectors from them several months before, they were sitting on the shelf awaiting pump installation.
 

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Discussion Starter #9 (Edited)
Just to proove my point here is the head i tore off the 2001 model i am breaking! I'm convinced it's even a good head. I think the gasket only got it. No cracks nothing anywhere else! What i mean is where it's scuffed here there is no crank gone through, could it be cleaned up? would a gasket re seal the area or is it for the bin? LOL. Well either way i will stay focused on the topic at hand and that is to use the Injection pump that came out of this model. I don't need a head but this would be a nice spare if it could be re-used.







 

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Discussion Starter #10 (Edited)
Sorry about the large pics, those are old ones from my 2001 Patrol teardown thread and i won't be using anymore of those from photobuket as i have future pics auto resized now from my phone to go to thumbnail which is easier on the brain to read the thread 😂 i just wanted to show the head and gasket from the 2001 model that the pump came out of. Not sure why two are watermarked and one is fine...stupid photobucket and it's crap :poop:
I hear Ya GU2, that sounds good! Yes baileys don't sound as good over the phone as the youtube video looks LOL!
 

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Discussion Starter #11 (Edited)
I tried to upload some of the older shots of the 2001 model but it seems like the size as i said is wrong but not to worry as any new pics like i say from my phone will be thumb nail size and i intend to keep on topic now on this thread about the pump install. So like i say it's now a question of what to do with the pump....get it tested or not first or just go for it! Mmmm...
By the way does any of you like my new timber wheels?? 😂 😂 😂
 

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Nothing wrong with large pics mate, I like them, show detail immediately. Your only limit here is 5mb. Yes love the timber wheels, when can you send me a set?
 

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Discussion Starter #13 (Edited)
Hahaha anytime GU2!! :ROFLMAO:

Ok so i am not going to take over the DI section with this thread and only intend to update when i have worthy news. How ever i have some worthy news right now and have made a start.

What i didn't know is this thing came with a second pump... they had the module off it and all the sensors hanging off it...that was a dudd pump too,it looks like someone tried a quick fix solder job on the PSG or a PSG change,i'm really not sure but from the pic you can clearly see the staggered cuts on the wires hence showing someone messed with it trying to get it going. So there is a pump in this Patrol (A bad one) and another second pump laying in the back of the patrol in a box.
Ok so i have established and confirmed both pumps are bad because i just got off the phone with the guy again and he said he got caught with two bad pumps (Ouch) i may have mentioned this already but i wasn't aware he threw me in both pumps.Good or bad pumps i'm happy to have both. One is a Bosch and the other a Zexel.

So what did i do sinse... ok so i done what we all would do,i went and got some fresh diesel in gerry cans because i was scared the sender unit wasn't working as the hand was so low in the red and wasn't moving with ignition,so it was a relief to know all was ok in that regard and now at least i know there is diesel in the tank.
So my first step was to change diesel filter because his looked just terrible to be fair and i don't want any restrictions and want to keep primer on while doing any sort of cranking on this.

It may be a good time now for me to say that this Patrol was at one of the best Diagnostics team in the county here (Not country lol) they are local Polish lads and have a great reputation. So everything has been checked .....they have two ECU's and two ignition key readers....etc..... long story short i was told it was the pump....a good scan tool had revealed this HOWEVER....i have my own doubts.

One issue i have straight away is the MAF sensor looks differnt...it looks more like something you would see from a Nissan bluebird (Will take pic tomorrow) but this alone will not cause a NO START situation. The Patrol would even start without it plugged in.
So moving on from there is something that is bothering me and it's the NATS light on the dash, ok the guys that were last at the Patrol specialise in these keys and Nats stuff so i trust that it's all been checked over etc... but i ran my own test and what i done was unplugged the harness from the IP in the Patrol and plugged it in to my own Zexel pump that i plan to fit....when i returned and turned the ignition i am STILL getting a solid RED light...once turning on the key it flashes a few times then stays on...this is worrying me and even plugged in to my own pump it's not going out.
Now some will report back with differnt & confused opinions about NATS and say that there Patrols always has a solid light but driving fine....others will say the light goes out as my own does... so this is a confusing thing and is going to make taking out this pump questionable for now especially after trying my own.They did too disconnect the return line from the banjo bolt and use a solid bolt in it's place,maybe they were having trouble keeping diesel at the pump or maybe they were trying to get diesel in the system faster...either way the old line and banjo bolt is still there and i'm not sure if this was going to achieve anything to be honest. See pics..

I did put in my freshly charged battery and hooked up some jumper leads to my own Patrol to give it the extra kick & like i say fresh diesel and used some Starting fluid in the airbox,i also primed the pump up and the Patrol turns over nicely and started to run a little on the fluid but does this rule out anything or does it add further confusion because some will say starting fluid will make an engine run without any source of ignition other will say the opposite. So these are the confused problems we all face in this situation.

The question still remains will i just go for it and try my own pump or is there some issue still somewhere with NATS.. despite it been fully diagnosed before as 'pump failure' i have my doubts.Even without starting fluid it don't sound 'Dry' like my own patrol did when the pump died but again more confusion because if the mechanical part of the pump was fine it would pump diesel in or if any mechanical part was dodgey it would too pump in fuel but at too low a rate...but if any electrical part of the pump was bad then it would pump in fuel but would never fire....
I need to have a good think about this!! lol
 

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You say that the banjo bolt was replaced with a normal bolt, isn’t there supposed to be a hole or holes through the banjo bolt? How is fluid supposed to get through without?
 

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Discussion Starter #15
Hi, yes it's on the 'Return' banjo the one with the none return valve in it. I presume they just done that because the IP wasn't pumping enough fuel to the engine or any and they were trying for a faster result to get more diesel to the injectors when they were cranking but to be honest this is just my own speculation as i never asked them.
 

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Hi, yes it's on the 'Return' banjo the one with the none return valve in it. I presume they just done that because the IP wasn't pumping enough fuel to the engine or any and they were trying for a faster result to get more diesel to the injectors when they were cranking but to be honest this is just my own speculation as i never asked them.
Could you post a pic of this please? I'm interested in what that was about. In my build thread there is a post about drilling out the standard banjo bolt which I did to get rid of a pulsation I was feeling through the fuel line, fixed it.

BTW, am PMing you pics about pump timing marks.
 

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Discussion Starter #17 (Edited)
So time for an update, and BTW thank you Ross for that link... it's just that scissor gear i am concerned about as this is all new to me. (Check my pics here now for that Banjo bolt) he just used a 'nut' to lock it off.

So today some good news and major headway (Pump off) Took me two hours,i surprised myself to be honest.I made a start at it but wasn't in amazing form about going at it... then i just decided to see how it would go so i got more and more interested in it once at it....so i started with the small stuff took intercooler off, and the throttle body. My first port of call here was to check the Glow plugs and i wanted to remove the Rocker cover anyway because i spotted one of the bolts was just finger tight :O

I am not joking guys but there had been so many mistakes made by the last mechanic that went at this thing that my mind is full of concerns.... Like i say i spotted the loose rocker cover bolt so i was definately taking everything off here if even just to check because i just don't trust the work done here and i really don't trust how this thing has been 'timed' up after the recent pump install.

So the things i found today i will state here in sequence, so i removed the Intercooler and throttle body, those were my first steps, i removed the Glow plugs and one was completly missing it's tip... while i tested the other three and they were fine (This would not cause a NO START) to my surprise though and it did piss me off was the main glow plug supply at the main connector was loose and just finger tight on the main glow plug bus bar....(Face palm) So i continued and made super progress and of course started to get more interested in it and it was time to go lower and remove the vaccum pump and power steering pump and put that aside.Then the timing cover was next, so i took plenty pics of the timing arrangment (which i don't trust anyway) and now it was time for me to get even more annoyed..... what mickey mouse mechanic was even at this!!! The timing chain main guide on the left he had the thread stipped and it was just finger tight on.... it was everyones luck this pump was bad and it never ran because this would have ended badly....so i need to retap that thread....he used a load of gasket maker in the hope that it would stay there (Another bigger face palm)

So i took off the timing chain tensioner and used the drill bit to lock it in place, took off the timing chain, i then undone the bung near to pump to lock the scissor gear and guess what!!?? It was all out of alignment :( i couldn't put the bolt through because none of the gear holes lines up...so this means some exta work for me now....i know this can be done back with a little fenesse.

So on i went and removed the front Injection pump small sprocket after taking chain off and the larger sprocket came off with it really easy.He did use the shim which i was happy to see in place between the pump and the large gear.I took the main EGR pipe from the intake manifold off, this was hard to access the lower inside bolt and was a pain but was much easier out of the way.

So i went up higher and removed the two top injector lines out of the way, and then lifted them out completly. Then i loosened the two lower ones and left them in place, Undone the rear three pump bracket bolts (12mm) and the three large pump bolts on the engine case,i as i said earlier went back to the bung i had undone under the pump sprocket and tried again to lock the scissor gear but it appeared to just not want to line up the holes in each gear (Or am i missing something here) ? So i am assuming the last twitt didn't have it timed right (God sake) so i left it as it was (scissor gear) and boom out came the pump! The scissor gear didn't seem to budge anyway!

I must say the biggest pain here was actually getting the pump out of it's location as room was so tight and the lower pump bracket bolt was a real PITA!!

What shocked me after i had the pump out was the main banjo bolt feed had no copper washers!!!! Man of all the things that could cause a no start this might i think!!#.'###

So all in two hours put to good use today,i will continue to fit my pump with the uncertainty of it not been a good or a bad one but that is what i started out to do so onwards and upwards!!

My biggest issue here is timing the whole thing back up.... thanks GU2 for the links and help time to read up on those!!!

Check out my pics here Ohh and the pump i just removed i think it looks like a PSG swap was attempted here as all the wires are staggered cut and resoldered-- check out the pics!

Dan
 

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Discussion Starter #18
Forgive the pics as they are in no paticular order as they all uploaded to my pc in differnt order...
 

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Discussion Starter #19
More pics hopefully showing all the issues too i mentioned!
 

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Discussion Starter #20
And the last few for now.. It is a Zexel pump also and i think the interesting part of this for me is the question remains is the pump i'm fitting a good one!! The stakes are high as it's a lot of work.
 

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