Injector Pump: Should I rebuild or throw this one away?

Hi All,


Long time lurker. I finally bought my first TDI a couple weeks ago: 2001 MK4 Golf with the ALH engine code. Really stoked.


I bought it knowing it had issues. I'm pretty handy with a wrench and knew it was going to be a fun project.


Now for the problem.

Previous owner ran some dirty Bio diesel in it. He replaced the injection pump 2 years ago with a new unit. ALso replaced the fuel tank, lines and filter.

I pulled vacuum on the system at a couple spots and confirmed no issue. Even removed the fuel sender cleaned and poked inside the tank to see only minor debris.

I opend the IP, Quantity adjuster has a lot of contamination / rust / coil paint that has flaked off. Diving further into the pump, I removed the metering block (assembly housing the QA coil / cam / spring assy) and found the attached pictures. Looks like surface rust on the steel parts in there :/. Not super happy, but I realize this may just need a new pump. Since this really is a project, I would like to avoid the cost of an IP.


I have a IP seal kit coming in the mail.


Questions:

1) I would like to take the IP into pieces, ultrasonically clean and reassemble. Is there a procedure to do so? I searched, but haven't found anything.

2) Has anyone done this with success before?

3) Advise please?
Thanks!

Uh..... yeah, all that nice stuff going into the injectors will do wonderful things to them....

Agreed. I'm not going to run it 'as is'. My questions were related to if anyone could point me in the right direction here short of buying a new IP. Thanks.

Salvage yard, buy a used one and hammer down

Some I've bought we're 30-50 bux and haven't had a bad one yet, I've found 2 or 3 11mm pumps that have been everything they were supposed to be


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WildChild80 said:

Salvage yard, buy a used one and hammer down

Some I've bought we're 30-50 bux and haven't had a bad one yet, I've found 2 or 3 11mm pumps that have been everything they were supposed to be


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Whoa, that's great! I'd like to go that route. I'll have to look around at my junk yards...not sure they have any TDI's there.


Since I am new to TDIs, is it only the VE pump that will work with the ALH motor?



Thanks

99.5 to 03 Jetta golf beetle.

I have a few spares bagged up for down the road problems if they arise.

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Row 52 is a great resource to search the yards so you can watch for them and not spend time talking to the retards working there

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WildChild80 said:

Row 52 is a great resource to search the yards so you can watch for them and not spend time talking to the retards working there

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Just checked all the pick-and-pulls around me...not a one diesel. All gassers.


What would it take to pry one of those bagged-up IPs from you?

I hate to but give me a day to think about it...I've got 3 of these things (ALH cars)

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All the parts except the QA are fairly easy to clean. It's a worthwhile core to a rebuilder so I wouldn't throw it away.

Please tell me that was homebrew biodiesel.
If not, do you know the brand name?

WildChild80 said:

I hate to but give me a day to think about it...I've got 3 of these things (ALH cars)

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Understood. I’d really appreciate if I could buy one from you for a reasonable price. You’d be doing me a huge favor to get the old girl running. Thanks again for the consideration.

Not sure the bio was homebrew, but from somewhere in Nor CA I assume.

those 2 wire ends on the quantity adjuster need to be soldered back in place?? how did you get them off ?? ....

my pump might need a cleaning . no start with a p1562 quantity adjuster upper limit reached, just happened today ... THANKS

jdbrinkman said:

those 2 wire ends on the quantity adjuster need to be soldered back in place?? how did you get them off ?? ....

my pump might need a cleaning . no start with a p1562 quantity adjuster upper limit reached, just happened today ... THANKS

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I was getting the P1562 and P1563 (upper / lower limit QA) error. That's one of the reasons I opened up the pump. Sure enough the cam wasn't rotating freely in the solenoid QA. Oh how i wish it was only a little debris and not this giant mess in there...yikes.

Those wires make contact under two left-threaded copper screws on the top board. I just unscrewed them and it released the wires.

burn_your_money said:

All the parts except the QA are fairly easy to clean. It's a worthwhile core to a rebuilder so I wouldn't throw it away.

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Thanks! I hope it won't come to that. I'd like to have confidence that I could disassemble the pump, clean and reassemble in my garage with basic tools and a ultrasonic cleaner...

Ever hear of anyone doing that...? With Success?

Well I do that regularly when I rebuild pumps but I'm also "factory" trained. If you know what surfaces are what, you can actually sand/wire wheel a lot of that stuff off. Mind you, there are some surfaces that if you touch with sandpaper they are done for. There are some passages in the pump that are drilled and then capped off with a ball bearing. You won't be able to clean those short of soaking and blowing cleaner through them.



When I worked in a fuel shop, we did rebuild a few pumps that looked as bad as yours. There were extra cleaning fees so typically the customer chose to buy a clean core and start there for about the same price.

rohls......If you want a pump from pick n pull you will have to monitor row 52 diligently......pretty much daily, for a tdi to hit the yard, then go and get it PDQ, before someone else gets it and puts it on ebay. PNP calls it a fuel distributor and charges about $36 for it ....... with their BS fees and charges you'll pay close to $50 out the door.
Or you could buy a used one off of ebay, about $150, 10 mm, very good chance it will work just fine.
I would not invest any time or money in the one you have.


just my .02 cents worth.

U4ick said:

rohls......If you want a pump from pick n pull you will have to monitor row 52 diligently......pretty much daily, for a tdi to hit the yard, then go and get it PDQ, before someone else gets it and puts it on ebay. PNP calls it a fuel distributor and charges about $36 for it ....... with their BS fees and charges you'll pay close to $50 out the door.
Or you could buy a used one off of ebay, about $150, 10 mm, very good chance it will work just fine.
I would not invest any time or money in the one you have.


just my .02 cents worth.

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Thanks a bunch! Yeah, I’m not willing to wait for a TDI to appear in the pick and pull....past that phase in my life. I searched a bit on Flea-Bay...there are a few, just you never know what you’re gonna get. I think I’d rather buy one from a fellow TDI Club member and have confidence it’s been refreshed by someone who appreciates these neat motors.

eBay is probably your best bet, just went through what I've got and I've only got the 11mm pump that shut down and the QA was full of metal and the 10mm that came off the car with unknown mileage, the car had been worked on a whole bunch before I took over. Thought I had 3 but I tore one down for a learning experience and some screws that stripped out

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WildChild80 said:

eBay is probably your best bet, just went through what I've got and I've only got the 11mm pump that shut down and the QA was full of metal and the 10mm that came off the car with unknown mileage, the car had been worked on a whole bunch before I took over. Thought I had 3 but I tore one down for a learning experience and some screws that stripped out

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Cool, no worries. Thanks for the help.

Dutch Auto Parts has some very reasonably priced IP's that have been cleaned and tested. Frans is a respected supplier here on TDIClub.

Nevada_TDI said:

Dutch Auto Parts has some very reasonably priced IP's that have been cleaned and tested. Frans is a respected supplier here on TDIClub.

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Very cool; thanks. I didn't find anything on their site, but contacted them via email.

If he doesnt respond quickly just call him, his shipping is very fast considering it comes from the netherlands. I got a shipping notice from him last thursday for some injectors and a turbo and it showed up monday! Great guy to work with.

U4ick said:

rohls......If you want a pump from pick n pull you will have to monitor row 52 diligently......pretty much daily, for a tdi to hit the yard, then go and get it PDQ, before someone else gets it and puts it on ebay. PNP calls it a fuel distributor and charges about $36 for it ....... with their BS fees and charges you'll pay close to $50 out the door.
Or you could buy a used one off of ebay, about $150, 10 mm, very good chance it will work just fine.
I would not invest any time or money in the one you have.


just my .02 cents worth.

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Still $50.00 for an injection pump is amazingly cheap. You go to any other wrecker that pump would be 3-4x that




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Down here in VA I usually pay between 30 and 60 for an IP

EDIT: yes PNP is by far the cheapest usually. I've got a place in Texas that sells transmissions for 99 bux and super cheap price on everything else

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Whoa. That is cheap...!

WildChild80 said:

Down here in VA I usually pay between 30 and 60 for an IP

EDIT: yes PNP is by far the cheapest usually. I've got a place in Texas that sells transmissions for 99 bux and super cheap price on everything else

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Thanks!


He responded today...!

casey823 said:

If he doesnt respond quickly just call him, his shipping is very fast considering it comes from the netherlands. I got a shipping notice from him last thursday for some injectors and a turbo and it showed up monday! Great guy to work with.

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