Injection pump repaired?

[superhl]

I would like to send my injection pump off for diagnostics or repair. I don't think DFIS exist anymore. I called Oregon Fuel Injection but they send it off to another vendor which I may do. Want to make sure I send to the correct place. Can you recommend who I should send it off. It will not hold prime. I did a seal kit install a couple of years ago. Re-sealed it but while I am working to get the O-ring on the head I heard like a spring noise. Not sure if a spring come lose but don't want to take that chance. Thanks

2002 vw new beetle 1.9TDI

 

[superhl]

Here is the name and how to contact them

dieselfuelinjectionservice

Diesel Fuel Injection Services – Repair and Service in Scappoose, Oregon (dfispdx.com)

 

[pkhoury]

I would like to send my injection pump off for diagnostics or repair. I don't think DFIS exist anymore. I called Oregon Fuel Injection but they send it off to another vendor which I may do. Want to make sure I send to the correct place. Can you recommend who I should send it off. It will not hold prime. I did a seal kit install a couple of years ago. Re-sealed it but while I am working to get the O-ring on the head I heard like a spring noise. Not sure if a spring come lose but don't want to take that chance. Thanks

2002 vw new beetle 1.9TDI

DFIS definitely exists, but I think they've been winding down their VE pump repairs.
I'm not 100% sure, but maybe try @Franko6? I'm also not 100% sure again, but I think @BleachedBora knows of someone who can rebuild it, too.

 

[superhl]

DFIS definitely exists, but I think they've been winding down their VE pump repairs.
I'm not 100% sure, but maybe try @Franko6? I'm also not 100% sure again, but I think @BleachedBora knows of someone who can rebuild it, too.

Thanks! I contacted DFIS and they are still rebuilding these pumps. I also called triplet out Waco Texas. He carries a two year warranty. $1025.00.

 

[03Golfer]

Could try Giles at performance diesel injection in Ontario, Canada. With the exchange rate, it might be favorable even with shipping.

 

[superhl]

I will send him a message. Thanks

 

[pkhoury]

Thanks! I contacted DFIS and they are still rebuilding these pumps. I also called triplet out Waco Texas. He carries a two year warranty. $1025.00.

If you're in Texas, you could also holler at Able Fuel Injection. I think they're in Lewisville or Denton. I've had them do some injector nozzles for me before, per @alphaseinor 's recommendation.

 

[AndyBees]

I would like to send my injection pump off for diagnostics or repair. I don't think DFIS exist anymore. I called Oregon Fuel Injection but they send it off to another vendor which I may do. Want to make sure I send to the correct place. Can you recommend who I should send it off. It will not hold prime. I did a seal kit install a couple of years ago. Re-sealed it but while I am working to get the O-ring on the head I heard like a spring noise. Not sure if a spring come lose but don't want to take that chance. Thanks

2002 vw new beetle 1.9TDI

It is not rocket science to remove the head for an inspection. I had a similar experience due to the big O-ring sticking to the IP head, I had to remove it. In doing so, bits did fall into the round housing. But, I was able to re-assemble and put it all back together. Almost, 80k miles later it is just fine.

This link is to my photo album containing photos of the work. Each photo will have some explanation/narrative.

ALH TDI Injection Pump Re-seal

forums.tdiclub.com

In the link below, there will be some of the same photos but more narrative. Also, in the link, scroll down to Posts: #770, 777, 778, 779, & 780 for the details.

ALH TDI engine transplant into '84 Vanagon

Head seal I thought you were gonna have Matt put seals in it at TDI fest. Wish I could do it. Well, the leaks stopped in a day or two after I got the engine running in the garage. I just assumed that it would do better with use.... and, actually, there were times it would start almost...

forums.tdiclub.com

 

[superhl]

It is not rocket science to remove the head for an inspection. I had a similar experience due to the big O-ring sticking to the IP head, I had to remove it. In doing so, bits did fall into the round housing. But, I was able to re-assemble and put it all back together. Almost, 80k miles later it is just fine.

This link is to my photo album containing photos of the work. Each photo will have some explanation/narrative.

ALH TDI Injection Pump Re-seal

forums.tdiclub.com

In the link below, there will be some of the same photos but more narrative. Also, in the link, scroll down to Posts: #770, 777, 778, 779, & 780 for the details.

ALH TDI engine transplant into '84 Vanagon

Head seal I thought you were gonna have Matt put seals in it at TDI fest. Wish I could do it. Well, the leaks stopped in a day or two after I got the engine running in the garage. I just assumed that it would do better with use.... and, actually, there were times it would start almost...

forums.tdiclub.com

Thanks Andy,
I am going to give it a try. Here is what concerns me and replacing all the 0-rings might resolve; the IP is louder than other TDI's. I purchased it from a nurse who was hit from behind. Her husband and a friend tried and tried to get it started. When I bought the car, the first thing I checked was the lift pump. The car was hit hard enough detaching it from the housing, Would cranking it over and over somehow damage the pump if no fuel was available? I am going to follow your steps and see it makes a difference.

 

[mogly]

Could try Giles at performance diesel injection in Ontario, Canada. With the exchange rate, it might be favorable even with shipping.

I'm not sure Giles has the testing for electronic VE pumps in house?

 

[03Golfer]

I'm not sure Giles has the testing for electronic VE pumps in house?

Either way, he does service and repair them, and his prices and quality of work have been good by me (and many others).

 

[IndigoBlueWagon]

D&W Diesel in Auburn NY and Alliant (Diesel Forward) in Windsor, WI both do TDI IP diagnostics and repair. I've had pumps rebuilt by both companies and they do a good job. I'd probably try Alliant first, as they're the Bosch master fuel distributor for North America. Eric in the fuel shop can help you out.

 

[AndyBees]

I'm not sure what you mean by ..."detaching it from the housing."

When a TDI runs out of fuel and the engine stops, the Injector Pump (IP) will be at least half full of fuel. Thus, cranking the engine to prime the fuel system and start the engine will not damage the IP. Now, a complete disassembly, cleaning, etc., and reassembly requires everything to be lubed with diesel fuel. The plunger fits so precise in the head that it can snap if it is not lubed.

If it has a "lift pump" it was installed by a previous owner. The VW TDIs with ALH engines did not come with a Lift Pump.

You can see the plunger in the diagram in this link. It is # 5. This is a VE pump for a 1.6 engine, but they are basically the same internally.

 

[GTiTDi]

"the IP is louder than other TDI's."

Sound of a worn out pump. They probably never put any lubricity additive in the tank

"I purchased it from a nurse."

My suspicions most likely confirmed

 

[superhl]

I'm not sure what you mean by ..."detaching it from the housing."

When a TDI runs out of fuel and the engine stops, the Injector Pump (IP) will be at least half full of fuel. Thus, cranking the engine to prime the fuel system and start the engine will not damage the IP. Now, a complete disassembly, cleaning, etc., and reassembly requires everything to be lubed with diesel fuel. The plunger fits so precise in the head that it can snap if it is not lubed.

If it has a "lift pump" it was installed by a previous owner. The VW TDIs with ALH engines did not come with a Lift Pump.

You can see the plunger in the diagram in this link. It is # 5. This is a VE pump for a 1.6 engine, but they are basically the same internally.

Andy,
When I started the project someone else informed me this model did not come with a lift pump but this car had one. The ladies husband bought it from his Dad which I am sure took very good care of it. He had starter issues most likely long cranks. I tried everything in the book to remedy the long cranks. Removed the starter at least 5 times. The last time the starter mechanic ask me bring the truck for them to test. He said the starter is not turning fast enough. I called Northwest fab who bought out Randy. He sent me a link to a starter which I purchased and solved the long crank issue. When I said detached, I meant the fuel pump form impact had come apart.

 

[superhl]

 

[AndyBees]

Well, long cranking generally means the IP has lost prime. But, I can see a starter being problematic, especially a high mileage one. I've preemptively replaced them at 300k miles and above. I cannot say I've seen one go bad before 300k miles. But, the history of the car dictates longevity of any unit.

As I said previously, I am not aware of any 2002 model New Beetle TDI coming from the factory with an in-tank lift pump.

That Injection Pump looks as if it has ingested some contaminated fuel.

 

[superhl]

Two months ago pumping fuel at Walmart took forever to get 10 gallons off fuel. The next day would not start. Video
Video 2

 

[IndigoBlueWagon]

Two months ago pumping fuel at Walmart took forever to get 10 gallons off fuel. The next day would not start. Video

Slow fuel delivery from the pump is a warning that the station isn't replacing their filters on a timely basis. Whenever I encounter that I stop fueling and go elsewhere.

 

[superhl]

Slow fuel delivery from the pump is a warning that the station isn't replacing their filters on a timely basis. Whenever I encounter that I stop fueling and go elsewhere.

I stopped purchasing fuel from Walmart! it is always slow!

 

[superhl]

Update:
I sent the injection pump to Frank for rebuild. Installed but took forever to start. I notice my wiring harness relays were blinking. Checked the hotwire that connects to the battery, wire had almost corroded into. I purchased this wiring loom form David at fast forward. Has anyone had any issues with this hot (red) wire. It is silicone wire. This is the 3r time I had to cut about five inches off and terminate a new ring terminal. When I strip the wire back, lots of corrosion kind of looks like a corroded battery. Lots of powder. What would cause this? After I re-terminated the ring terminal, started immediately. Replaced my metal tank with a new metal aluminum tank. Frank said the IP was contaminated really bad.

 

[03Golfer]

Interesting about the wire. I just finished installing a harness from Fast Forward. That wire was one of the things I wasn't keen on - reminds me of the wiring that comes with cheap subwoofers. I will keep an eye on it for corrosion. What conditions do you drive in? Any road salt? Do your battery terminals get any corrosion on them? Only 2 things I can think of off the top of my head.

 

[superhl]

Interesting about the wire. I just finished installing a harness from Fast Forward. That wire was one of the things I wasn't keen on - reminds me of the wiring that comes with cheap subwoofers. I will keep an eye on it for corrosion. What conditions do you drive in? Any road salt? Do your battery terminals get any corrosion on them? Only 2 things I can think of off the top of my head.

Sorry. I been killer busy. The whole wire was corroded. I replaced with a new wire. No corrosion any where else. No doubt cheap wire. Everything comes from China now days! I'm in NC so dry mostly dry. No salt....I sent the pump to Frank in Missouri for repair. I Installed, timed and IQ'd. Drove it down the road ran awesome. Got back to the house, shut it off and tried to restart and would NOT start. I cracked the lines and all kinds of air. While the truck was down, installed new aluminum tank. Made sure no leaks. Tonight I bled the lines, started it up runs fine until you put a load on it. Started 500' to moms and turned around and it shut off. My neighbor and his wife pushed it back to house Bled lines again, lots of air, started and runs fine at idle but if I put a load on the pump I get all kinds air. Praying I don't have to send pump back, but not looking good! I'm hooking a 1/2 container of diesel directly to pump and see what happens. What a pain! New Tank

 

[AndyBees]

Seems your fuel system has a major air leak which is likely at the filter or one of the connections. Keep in mind, the VE Injection Pumps moves a lot of fuel in a matter of seconds. The internal Vane pump is strong enough to collapse a fuel tank that is not vented (happened to me on an MK1 Jetta with the little 1.6 diesel engine.

My homemade IV set-up works great for a number of things related to the Injection Pump.
It is primarily a plastic Jif Peanut Butter jar, filter, hoses, etc., and held together with JB Weld. I made it in 2012 and have used it many times down thru the years. The JB Weld is very compatible with Diesel Fuel and additives.

 

[superhl]

Thanks Andy! What kind of filter is that? I going to make something like this. I did order enough fuel line to bypass Cat filter, and electric pump. Waiting on amazon to deliver. I update the post above with the aluminum tank I purchased. Maybe the lift tube getting air. I am to drop the hose in through the where the cap is installed and tape aroung it. If I don't get air, then I know it either the cat filter fittings or the electric pump or the filler tube. My luck there is pin hole in it.

 

[AndyBees]

It is a simple filter for gasoline. I drilled a hole in the bottom of the plastic jar. With JB Weld applied, I pushed the nipple of the filter up inside the jar. The nipple protrudes about an inch or more off the bottom of the jar.

 

[superhl]

Tried something similar with 1/2 quart jug with hole in cap but not sealed. Most of the fuel splashed out I guess. Once started it seems to run with no issues. Only when I put a load on it that it crashes. I bleed the line, lots air but once re-primed it runs at idle ok. Hopefully tmr evening I can get some time to create what you created but a quart container.

 

[AndyBees]

Considering the ALH engine only burns about 2.5 ounces of fuel per mile at 50 mpg, at idle the amount is extremely small .... something like 0.8 liter per hour.

So, a small container with a small amount of fuel works just fine in an IV set-up. Also, rather flimsy hoses reduces the amount of engine vibration transfer.

Yes, my container allows air to enter around the center support piece. I always screw the jar lid down tight in the event I might drop it.

 

[superhl]

I arrived home late tonight. I reprimed, let idle for 30 minutes. No issues. Drove up and down my path to barn twice, Died, reprimed and drove back to carport. I going to make your device this weekend and give it a try. Hoping it is not the pump.

 

[superhl]

Andy,
I built an IV and connected to IP pump. Runs great and have not had to re-prime the pump Also, runs quite. So, now we know its not the pump. Next, I am going to by pass the electric pump.
IV