DiD injector pump DIY reconditioning?

[El_Freddo]

G’day all,

Is it possible to diy a injector pump reconditioning job at home?

I’m asking after reading a post about the failure being due to a dead bearing that *could* occur around the 300k km mark from Ghendo:

...My local diesel specialist warned me to have it serviced when I got 250,000km. on the clock, at a cost of around $1,500, however it was one of those things I kept putting off and ‘gunna-do’, until the day the engine wouldn’t start and when the pump was pulled apart it was full of metal filings from the disintegrated $25 bearing – hence a $5,500 job to replace most of the pump as the filings had penetrated everywhere. The speedo read a whisker under 298,000km.

I would think that most of the engines with these pumps on them would be getting up around the 300,000km. by now and anyone who has one that hasn’t had the pump services, should attend to it pronto.

We’re now at 330k km, no symptoms of an issue and I’d like to avoid a costly pump replacement with some preventative maintenance.

Why DIY? Because that’s what I do and I don’t know any good diesel specialists in the Bendigo region. If I did go to a specialist it’d be with the pump only to keep the cost down.

Anyone done this before? Or anyone got a dead pump I can pull apart to see what’s involved before potentially getting in over my head on a working pump?

Cheers

Bennie

[Nab]

Not sure if it’s possible on the gen 3 pump. Most diesel repair shops can’t/won’t repair them as they don’t have the right equipment to do it, I think there is only a handful of places are n Australia that can do it.

But if you give it a go be sure to post it here!!!!

[GHendo]

I wouldn’t think it a good idea. There are other parts that should be replaced when the pump is dismantled even if the bearing hasn’t failed yet. I saw the pump when it was in bits and unless you have had experience in this field you might end up with a bit of a catastrophe. I know Lismore Diesel has spend thousands on specialist equipment to work on these pumps and they wouldn’t have done that if it wasn’t necessary – some of that would be tools to assemble and reassemble let alone testing. Also, you need a special room that is completely clean and dust free.

I do a lot of mechanical work on my own vehicle and the farm machinery I have here but I’d never tackle pulling one of those pumps apart.

Cheers
Geoff

[pharb]

What Geoff said.

I'm a heavy vehicle mechanic and I dispise farming out anything I think I can do myself. Even when it came to building my house, including plumbing, electrical etc (unde supervision of licenced tradesman!!), but I wouldn't contemplate rebuilding an injection pump, or injectors.

It isn't just a matter of replacing components. Alot of components have to be set and adjusted appropriately, which means putting it on a test bench to replicate actual running. Some of these adjustments are performed with shims, so put on bench, gauge performance, take off bench, remove/add shims, retest, reshim until correct.

Having siad that, if you were just going to replace this bearing you might be able to do that yourself, but I doubt it, and if you have the pump off you may as well get the rest of it checked and serviced as required as well.

[El_Freddo]

Thanks for the heads up. Sounds like an interesting process!

I’ll start hunting around Bendigo to see who knows what in terms of these pumps.

I’d rather throw some money at it and know it’s good than have a failure, flat bed and pump replacement costs.

While it’s out I can tend to the intake clean and see why the turbo output is oily - found that today, probably a front seal. That’ll be fun.

Cheers

Bennie

[maxwin]

Hello,

Can be done but you must have some mechanic skils.. what breaks on these pumps.. is the main bearing, and the timing piston sensor, the metal rod breaks, and destroy more things in the pump.

The most important thing for these pumps, check your fuel lines ( Tank filler ) and clean the tank..


On youtube a lot of russian companies who are rectifiang these pumps, and its nots so complicated as it looks.

For example look here, lot of videos about this:

https://www.youtube.com/watch?v=FzmOj11MX8I

[El_Freddo]

Thanks Maxwin, I’ll have to look into this further.

Cheers

Bennie

[Poita]

Yeah it's a big job requiring specialist equipment. I have a thread on here listing all the workshops that we know of that can service them.

I found though, that it was only a little more expensive to buy a brand new pump (and it comes with all new sensors). So I went the new route.

[Trojan]

Yeah it's a big job requiring specialist equipment. I have a thread on here listing all the workshops that we know of that can service them.

I found though, that it was only a little more expensive to buy a brand new pump (and it comes with all new sensors). So I went the new route.

Same experience Poita. New pump from MM was cheaper than a Lismore reconditioned with postage of my faulty pump as a core back to them.


They were very interested in the price that I was able to negotiate with Mitsubishi which didn't give me a lot of confidence in dealing with them.

[maxwin]

Have done some pumps here in spain.. some parts of zexel are not so expensive here.. and all available, don.t know about australia..

Sometimes the high pressure side is also damaged, on the european ebay .. can find them reconditioned for a reasonable price.. bulgarian and russians are specialist in this.. youtube also your friend..

Don,t forget the clip ( number 18 ) before dismantling the main axle..

Try later to upload the exploded view.. ( upload error )

[maxwin]

maybe also interesting..

[maxwin]

This one.. ( maybe already known )

[sharkcaver]

I have a failed pump that had the dreaded code 48 here at home (Perth). Free to a good home should someone want it.

[ItsAllNew]

Hi Bennie, I'm also in Bendigo, and have a NP DID Pajero.

Wondering how you got on with yours? Reconditioning and replacement of bearings etc?

Cheers, Heath

Sent from my SM-G930F using Tapatalk

[El_Freddo]

Hi Bennie, I'm also in Bendigo, and have a NP DID Pajero.

Wondering how you got on with yours? Reconditioning and replacement of bearings etc?

Cheers, Heath

G’day Heath,

I haven’t touched ours - I was looking at it from a preventative maintenance perspective. I don’t want to be caught with my pants down so to speak if/when the pup issue rears its ugly head.

Are you visiting Bendigo or moved here recently? There are loads of Pajeros getting around with lift and six tanks of various sizes. Our Np is pretty stock atm.

Cheers

Bennie