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Discussion Starter #21 (Edited)
Edit: Go back a page on this thread for latest updates I already knew this pump was scrap as it was completely exposed to the elements for how ever long engine was sitting in his shed but maybe a good strip and clean won't hurt or at least a closer look! 馃槅 but I wanted to strip both pumps anyway and take a look,that was always my plan馃槈 Nothing to loose! Ohh and here is my new shed. Coming along nice 馃槃馃憤
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Discussion Starter #22 (Edited)
Ok before putting up my detailed pump strip down pics. I want to get back to the Patrol and the few other jobs I got done. So I took off both rear wheels and fitted two new tires I had already. Then I got lucky and bought a spare wheel that was missing for 25euro a mint alloy wheel may I add 馃槂馃憤 talk of a good deal but I know the guy and he didn't need the wheels anyway so didn't mind selling them separately. Also I fitted two head lamp bulbs that were missing so this ruled out any other electrical gremlins.馃憤 I then gave the Patrol a good wash outside and the wheels came up mint 馃憣
 

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Discussion Starter #23
Ohh and by the way the above pump removed from new engine is a Zexel unit also!
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Discussion Starter #24 (Edited)
Back later with plenty updates on the progress with pumps etc...for now the phone is terrible to use and I want to wait to use my PC as it's faster. 馃憤 I have lots of pics to put up 馃槈
 
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Discussion Starter #25 (Edited)
Ok so I stripped both pumps with the intention of having a closer look and to see if I can put together one good runner from them both. Nothing to loose so I don't mind 馃槂And I can start by saying this is totally worth doing just to clean alone so long as you are neat/tidy. To start with,The pressure control valve on top /front of the pump is prone to getting clogged as is the timer piston/ valve assembly (Bottom of pump)is especially prone to clogging up with crud as are the four injector line injector fittings to the rear of pump. Upon stripping both pumps one was mint looking and the other was downright nasty. Both pumps the injector line fittings to rear were very dirty and compressed air helped here, there are three jets on each one to clean and they don't take much at all to block 馃槈 Also watch the copper shims/ seals once refitting.ESC's were spotless looking. Even on the clean looking pump there was areas quite clogged (Timer piston assy bottom of pump) After pulling out both distributors from the rear of the pump you can make out 4 tiny filters here inside the pump which I used compressed air to clean thoroughly. From here on in to the middle of the pump in at the main large bearing you have rollers X2 which sit in to housings and slip back in to a slot near the vane in the center. It's fairly simple but on one pump these were completely seized!! The other pump they were perfect and dropped straight out with ease. These are to rotate freely to direct flow and regulate pressure in the high pressure part of the pump. Around the body of the pump there are plenty of screws you can undo for cleaning and access and also when you remove top ESC body you have greater access to front of the pump for extra cleaning. From here on I'll let pics do the talking. I have my pump almost ready to be fitted. It's worth a shot. Few points to take note of here, be CAREFUL putting back in timer piston and watch tiny jets/ holes all align as they came out. Make sure when fitting back rear distributor section to put everything as it was removed. Good common sense required here!! Finally I have no specialist equipment to test anything this is JUST a cleaning process and to swap out any sensors I think psyically looked bad to me. Again, I have nothing to loose before sending this to a specialist.馃槈 Let the pics do the talking from here on of the two pumps! Goes without saying better off to replace all seals after doing something like this again I got nothing to loose!
 

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Discussion Starter #26
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Discussion Starter #27
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Discussion Starter #28
So you see one pump was manky and the other was much cleaner but on both pumps and it amazed me was the timer piston valve on the very bottom both were very dirty!! Worth cleaning this bad boy alone I reckon on any pump if you are handy with the diy mechanics. I am excited to test my new pump soon 馃槈馃憤
 

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GUII ZD30DI Wgn
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Hi Dan, not sure if you ever read it but a nice little mod to the VP44 is drilling out the main fuel in banjo bolt, here's a link to the actual deed but you can start at post 506 for reasons why it was looked at, also a post by someone else that Cummins were doing it on some engines.
PS take no notice of the wording of the link, it takes the wording from the first post on a page, I'm still arguing with our owners about this.
 

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Discussion Starter #30
Cheers GU2. I'm going to try this pump but won't be alarmed if it don't work. So far I am getting quotes of 900euros + vat to repair it yet none of them have even seen/ tested pump yet 馃ゴ What especially annoys me about Diesel specialists is they never even tell us what work was carried out. If this don't work I am going to try to find a used one. My time/ labour in to this project will be high already so it's stupid to pump too much money in it. By the way on that timer piston it's all one solid unit on a spring so no need to worry about tiny parts been lost. There are lots of tiny pin holes very worth getting compressed air through! These ones were very dirty looking. 馃槈
 
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Discussion Starter #31 (Edited)
Ok, so remember I put up two pumps, one very dirty and seized inside and the other one spotless and looking like new inside!! So
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here is where it is at. I took a few hours away from my work today and removed out the IP that I most recently fitted and like the other pump I tested unfortunately It's not working! So, no diesel going to injectors on this pump and the other pump ( the one that looks very dirty inside) was pumping diesel up but it looked intermittent,meaning one sec diesel is coming and then nothing at all...this wasn't an air lock,this is after turning engine over many many times. The engine is mechanically 100percent,I can keep it running away on starting fluid.So one pump is getting a signal to 'fire' ( the dirty looking pump) and the other pump absolutely nothing at all... No diesel going up at all from that one. Now, here is the thing, out of the Patrol the cleaner looking pump when turning my hand is pumping out the rear at great power...each injector exit from the pump is firing diesel. Now the other pump (Dirty looking one) is not pumping so good even with my hand. Long story short I think I could be lucky here, I think the nice clean looking pump could be mechanically sound BUT not getting any signal to 'Fire' that also means no timing or sensors would be working without the electrical signal. And I think there is a chance the other bad pump that looks terrible inside it is mechanically not so sound. So, I have decided to stagger cut the wires ( I can't take out bottom sensor as special tool required) so I have decided to stagger cut 4 wires and swap ESC over to the good pump. Worth a shot I think 馃槃馃憤 Now this is only my theory and could turn out to be a load of crap.馃ぃ.. Who knows till I try it. Like I keep saying,I have nothing to loose 馃槈 All I have to do is resolder the wires together and I have invested in a very good soldering set up in recent times for other uses so that's a bonus. Note pic also of white sensor I can't remove. That needs specialist tools for sure!! Even with screws removed and tapping with hammer and screwdriver around it's mounting plate there's no budge...the metal plate I even distorted it but that sensor won't move. So it's staying put!
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Discussion Starter #32
Ok things are going good and I am just doing the brain transplant as I write this! 馃榾 "The man with nothing to loose may have everything to gain" 馃槈馃憤
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Discussion Starter #33
All ready to go soldering! 馃憤
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Discussion Starter #34 (Edited)
Ok guys and girls a big breakthrough! I found one of the timer pistons to be faulty in the good looking pump!! Let's hope this is the problem here. I highly recommend you watch my video here. It's good to give back stuff here to this forum every now and then! I am on here a long time and have had plenty help here in the past especially also from GU2. Hope this vid helps guys馃槈馃憤 Let's try to understand the basics of these pumps here a little better if we can. Every day is a learning day.(Edit: trying to upload vid but can't) 馃槕
 
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Discussion Starter #35
Vid won't load ....anyone tell me how?
 

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Vid won't load ....anyone tell me how?
Hi Dan, how are you loading video? you cannot directly load vid from phone etc, it needs to be loaded via a 3rd party, I use (free) Vimeo for vids specifically for here or youtube for some others.
 

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Discussion Starter #37
Ohh ok. I was trying to via phone in the settings here. Ok I will do that tomorrow as is bed time now.Something very interesting I found in the both timer pistons. Eye opening indeed馃憖
 
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Discussion Starter #38 (Edited)
Ok I will load up video later of timer pistons. Still trying to figure best way to do it. As you said GU2 I may try Vimeo or my own youtube account. Anyway, more good and bad news for me... Spent a few hours at it this morning after getting pump ready last night,got all soldering finished and fitted pump this morning,timed all back up and ready to rock. Good news is it's firing diesel to injector BUT not enough high pressure to crack injector... So this is where it is at. I have just got some starting fluid and bled the system so I'm going to try again now. To be honest I think pump needs work done and I won't hold my breath. The last good pump I fitted to my other Patrol months back didn't need much cranking at all before it was trying to kick. This one, no kick at all... Tragic thing is it could be one of the sensors only. Guess we will never know!! I'm going to try again and will report back but it's looking like another pump maybe needed here or sent away for rebuild!! I will see...I do know the ECU an all it's sensors on it together can be bought on eBay as a kit but numbers must be spot on and correct and an easy fit but that's a gamble too if the problem still lies elsewhere...
 

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Assuming you have followed the procedure to get fuel to pump, through and to the injectors and seen the effect with GP's out. As you may know I have just replaced cyl head so gone through this process once more having been through it already a few times with other mods, the interesting thing is ICV% always starts low, it was in low 40's and slowly increased to 'my' normality of 53% at 750rpm idle, jumping to 55% when neutral switch disengages.
 

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Discussion Starter #40
Yes I have loosened the Banjo bolt and bled the system well. It was turning over quite a while then the 'loose' injector line started to shoot fuel out. To be honest I'm amazed it's not running. The other pump wasn't sending you any fuel through the line, this one is. For now I sort of got fed up with it and condemed the pump but should I try other things? I had glow plugs out to start with but with engine turning over the oil flows in to the pistons and us been thrown up everywhere so I put them back in. Maybe I should run more tests before writing off this pump? Any thread on your cylinder head job GU2, well done!! A pig of a job I imagine but one on my bucket list. While I have removed heads I never refitted one.
 
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