In detail: photon 1099 fuel pump do-it-yourself repair from a real master for the site my.housecope.com.
There is no more complex and critical unit in a diesel engine than the fuel injection system, more precisely, its main part - the high-pressure fuel pump. Many mating parts, high-loaded units, the presence of a precision dosing system, make the repair of the injection pump a difficult task even in service conditions. It is all the more difficult to repair the high pressure fuel pump of a diesel engine with your own hands.
In automotive technology, almost everything is repaired, except, perhaps, individual oil seals and cuffs, the repair of which is impossible without special materials. The complexity of setting, diagnosing and repairing the injection pump requires the employee to have skills in working with precision mechanics.
It is simply impossible to adjust according to the factory parameters, without a special diagnostic stand for the repair of the injection pump. During the diagnostic study of the injection pump, it is necessary to check:
cyclic supply of the high-pressure pump, in the entire range of revolutions of the injection pump shaft, at start-up, and after cutting off the fuel supply;
stability of the developed pressure;
uniformity of the injection pump delivery to the fuel injector.
Even having access to a diagnostic stand, and having studied the issue of repairing a high-pressure fuel pump using numerous videos, it is very difficult to qualitatively check and evaluate its work.
In heavy diesel engines, plunger, in-line injection pumps are used. In maintenance and repair, such devices are more difficult, since they require special equipment for its disassembly, therefore we will not consider such high pressure fuel pumps and their repair.
In a passenger diesel engine, a distribution type injection pump is almost always used. Unlike in-line pumps, in a distribution pump, the force is transmitted to the plunger using a profiled cam washer. The design of the injection pump turned out to be more compact, but it is hardly simpler to expect to carry out its repair on the knee.
Video (click to play).
The most famous and affordable is the Bosh VP44 injection pump. Often, the need to repair the pump internals arises when:
poor traction and incomplete combustion of fuel even under ideal conditions - in the absence of load and a thoroughly warmed up engine;
a sudden failure and stoppage of a diesel engine under load, which is called “death on takeoff”. Usually the scanner in such cases diagnoses the code P1630 and P1651.
the appearance of a diesel fuel leak in the area of the gland seal of the central shaft of the injection pump.
Therefore, we will restrict ourselves to the issue of repairing the injection pump with our own hands by replacing the seals and eliminating the scoring of the working surfaces of the parts.
Before disassembling the pump drive shaft seal, try to move it radially. If play is felt with your hands, it is possible that the reason for the leakage of fuel is the wear of the working surface of the shaft or requires repair of the bearing.
A large number of split planes and mating surfaces of parts required the use of a large number of seals and glands. As a rule, they are made of quality material and last long enough until they are damaged during repair or maintenance. In this case, standard repair kits are used for DIY repair of Bosch injection pumps.
It is quite easy to replace the seal on the shaft position sensor and on the automatic injection timing during repairs. For a better fit, you can drip a few drops of spindle or engine oil onto new rings and rubber bands.
For preventive repair of a Bosch injection pump with your own hands, you will need to disassemble the pump in approximately the following order:
remove the metering valve from the end of the injection pump. To do this, unscrew the four screws of the pressure plate, carefully release the cable of the injection advance valve. By removing the three screws securing the metering valve, you can carefully remove it from the seat;
by unscrewing the fastener on the top cover, you can remove the control board and gain access to the electronics;
we set the position of the shaft, as shown in the photo, remove the camera and get access to the insides of the injection pump;
after dismantling the bearing using a special puller, we get the opportunity to study the potential culprit for the poor performance of the injection pump - the piston of the injection advance unit. There is often surface wear and edge scuffing on the part. You can try to make repairs by polishing the surface, replacing the whole part is much more expensive.
After the repair, the assembly is carried out in the reverse order with the washing of the parts with diesel fuel.
Often, in addition to scoring, on the surface of the pistons there is another reason why the injection pump does not develop the required pressure. This can be due to debris, films or wax build-up on the filter screen inside the pump. There is a mesh on the side of the inlet pipe. Rinsing the channels is a troublesome and ineffective business, it is easier to remove the mesh and blow it with compressed air.
Torn pieces of debris can jam the plunger piston or even break or break the pump drive shaft. Therefore, cleaning should be done very carefully to avoid contamination of the internal cavities of the pump.
Among the many reasons for the failure of the electronic "liver" of the injection pump, the most common is the breakage or burnout of the contacts of the control board and the failure of power transistors. If the knowledge and skills of working with electronic devices allow to carry out a "continuity" of the transistor performance and repair, it is worth trying to identify the cause and replace the culprit with a serviceable element.
To check the condition of the "culprit", you need to carefully open the black cover, which is tightly seated on the rubber seal with screws. It should be removed carefully so as not to damage the seal itself.
The reason for the failure of not only the transistor, but also the entire board could be air trapped in the cavity due to poor performance of the drainage system or the check valve. Often, they try to eliminate the airing by spinning up with a starter, hoping to pump diesel fuel into the high-pressure fuel pump in this way. At this moment, the transistor is open and loaded as much as possible, which leads to intense heating. In an air environment with poor heat dissipation, it will inevitably burn out. In some German cars there is a protection that prevents an attempt to start the engine in the absence of fuel in the highway. For this, a fuel sensor in the tank is used.
Failure of the transistor can be established by "dialing" a tester or by its appearance. The best option for repairing such a malfunction would be to replace the entire control board. Perhaps it is more expensive than soldering, but it will give guaranteed quality and stable operation of the injection pump after repair. As a last resort, give the board and the transistor for soldering to electronics specialists.
When installing and reassembling after repairs, check the tightness of all fasteners.
If during the audit you did not make rash and unreasonable replacements of parts, the assembled pump should work with approximately the same parameters as before. Bosch EPS-815 stand is used as a standard for testing and adjusting injection pump after overhaul.
The video shows how to raise the plunger pressure in a Bosch VE injection pump:
Prices 9000. 9000 rub.
The timing 2. 3 days
The high-pressure fuel pump Foton 1099 is a reliable unit, one of the main elements of the fuel supply system. Thanks to him, fuel is supplied to the engine cylinders under a certain pressure.
The most common failure of the injection pump is the failure of the injectors. The main cause of unit malfunctions is the low quality of the fuel used. This leads to rapid wear of pump parts due to their contamination with diesel combustion products. The engine loses power, rpm starts to “float” and fuel consumption increases. Repair of fuel injection pump Foton 1099 should be entrusted to professional mechanics. This will help to avoid malfunctions during further operation.
Incorrect adjustment of the device leads to a deterioration in the quality of exhaust gases, unstable operation in idle mode, and a decrease in efficiency.
System malfunctions lead to the following consequences:
reduced power and stability of the engine;
there are extraneous noises;
there is a low compression of the system.
Our service center carries out a comprehensive repair of the Foton 1099 injection pump, replacement of spark plugs, oil seals and other elements. We have been performing all work on time for over 16 years. All works are guaranteed for 12 months.
Driving safety is ensured by the correct operation of all vehicle systems. Since the high pressure pump is one of the most complex units of the fuel system, professional mechanics should be engaged in its repair. Contacting the BOSCH Diesel Center means saving time and money on overpayments for the purchase and repair of parts.
