DIY gas pump repair

In detail: do-it-yourself gas pump repair from a real master for the site my.housecope.com.

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Now it is difficult to find a modern non-injection vehicle. We can say that this type of car is confidently replacing old carburetor cars, and continues to do so further.

The main difference between these two types of cars lies in the structure and principles of operation of fuel systems. In some cars, carburetor-type fuel systems in which fuel, under the action of a mechanical gas pump with low pressure, enters the carburetor.

In another type of car, injection, the fuel is already under high pressure under the action of an electric fuel pump.

The operating speed of modern gasoline pumps, in contrast to old mechanical ones, is regulated by an electronic control system.

With the help of this system, the composition of the currently required fuel mixture and the required pressure are calculated, which, in turn, creates an electric fuel pump.

But due to the fact that the devices work under high pressure and make a lot of noise, they tend to heat up quickly. To cool them down and reduce the noise level, they are specially placed in the fuel tank.

Video (click to play).

However, there are situations when all the measures taken do not save the situation, and the device fails.

We will talk about the repair of the gas pump.

Only electrical devices that are on injection vehicles will be considered here.

To repair a gasoline pump, you need to know briefly its structure and principle of operation.

The fuel pump of an injection vehicle consists of a body, an electric motor running on direct current, a rotor, rollers that play the role of working bodies, a filter mesh, inlet and outlet pipes, a one-way valve.

The principle of operation of the device is very simple.

You start the car engine by turning the key in the ignition switch, and the computer sends a signal to the electric motor of the gasoline pump and starts it. Under the action of an electric motor, fuel is pumped.

After two seconds, the computer waits for a confirmation signal from the electric motor that it is running. If there is no such signal, the computer stops supplying DC power to the device. This is done to prevent the pump from burning out.

Through a filter mesh and a one-way valve, fuel enters the fuel filter, is cleaned and then enters the engine through a system of pipes. While the car engine is running, the fuel pump is running.

The practice of using electric fuel pumps has shown that their service life directly depends on the quality of the fuel that is poured into the car's tank. If you drive on domestic fuel, then do not expect that the device will last more than 3 years.

Of course, in the event of a breakdown of the latter, it would be best to replace it. However, their cost can reach from 50 USD. and higher. Therefore, it would be advisable to carry out partial repairs yourself. Why partial, read on.

The easiest way of repair is to assemble one worker out of 2 - 3 units lying in the garage, replacing only the slide-gate. But, unfortunately, not everyone has spare fuel pumps.

If you have an imported device, then it is more difficult or you will have to buy a new one or contact a specialized workshop. But even not all workshops undertake to repair imported gas pumps, since it is very difficult to find components for them.

Some workshops got out of this situation thanks to the independent production of working parts of devices produced by various foreign manufacturers, the main of which in this market are BOSCH DENSO, WALBRO, PIERBURG, AS, VDO.

Having carried out a spectral analysis of the material from which the parts of gasoline pumps are made, they learned how to make similar units of poor quality, which made it much cheaper to repair them.

Thanks to this, you can even completely restore a failed device that was previously planned to be replaced.

But there are only a few such workshops and you need to know where they are.

Let's look at the reasons for the failure of the fuel pump, in which it is necessary to repair it.

In general, as you probably understood, it is difficult to repair a gas pump yourself, especially if you have an imported version. It's easier of course to replace it, but if there is an opportunity to save money, why not give it a try.

The main most common cause is a breakdown of the electric motor.

The weakest point in an electric motor is its brushes and collector.

Pay attention to this when inspecting the motor.

It will be difficult to find brushes for an imported gasoline pump. Some specialized workshops have learned how to independently make brushes for such units. In terms of their chemical composition, these brushes are no different from the original brushes.

If a collector is destroyed, then it must be replaced with a new one or restored, which you cannot do without a specialist.

Failure of the plastic coupling. Thanks to this clutch, the pump rotor is connected to the armature shaft of the electric motor. The clutch should be replaced with a new one.

Again, this is a problem for imported gasoline pumps. Good workshops have established the manufacture of such couplings using special molds.

The motor armature itself may also fail. In this situation it is necessary to rewind the anchor.

Other reasons for the breakdown of the gas pump directly depend on the type of the pump itself.

Breakdown and types of fuel pumps.

  1. Gear type;
  2. Vane-type gasoline pumps.

There are gear-type devices, which are now widespread due to their low price. The main manufacturer of such pumps is the company Bosh.

As well as vane gasoline pumps. These units are more expensive, but much more reliable than analogs of the gear type, which are very sensitive to the quality of gasoline and do not serve for a long time in our operating conditions and often jam.

In a vane gas pump, the working element is not two gears, as in gear-type pumps, but special rollers.

What kind of breakdown is considered serious.

It should be understood that if some kind of breakdown has occurred in the fuel pump and the cause of this breakdown is not the electric motor, although this is also serious, then this breakdown can be attributed to serious.

Repairing a gas pump, especially an imported one, you are unlikely to do it yourself. Even not all repair shops undertake such repairs, but immediately recommend replacing the device.

Due to the fact that gear pumps in our operating conditions often fail, some workshops convert them into vane pumps, and although it is expensive, it pays off.

As you already understood, repairing the fuel pump of an injection car is much more complicated than a mechanical carburetor pump. Therefore, you should not resort to self-repair of such a gas pump.

For this, there are specialized workshops for the repair of pumping equipment.

However, in order for your car's fuel pump to last as long as possible, follow the advice below:

  • try to use only high-quality gasoline;
  • pay attention to the cleanliness of the fuel tank, periodically flush it;
  • if you removed the gasoline pump, store it in gasoline so that moisture does not get in;
  • if possible, change the filter nets that are inside the unit;
  • do not allow the pump to hit, fall, etc. he does not tolerate external mechanical influences well.

Repair the fuel pump only in specialized workshops that only repair the corresponding equipment.

One of the most reliable and most adapted to our operating conditions and our gasoline, among the imported counterparts, are the Bosch slide (roller) type pumps.

Next in terms of reliability are VDO, PIERBURG devices also made in Germany.

The next most reliable pump is the WALBRO pump made in America.

Next in terms of reliability is DENSO Corporation (head office in Japan, in Europe, office in Holland).

Among domestic gasoline pumps, Zhiguli ones have proven themselves well.

The VAZ 2106 automobile gasoline pump is an integral part of the vehicle's fuel system and plays an important role in the operation of the vehicle. Basically, on modifications of the VAZ 2106, 3 models of gas pumps are used: DAAZ, produced at the enterprise in Dmitrovograd; "Pekar", developed by a company from St. Petersburg and "Saratov". Over the years of production of passenger cars at the VAZ enterprise, the range of manufactured modifications has gradually changed with the transition in the equipment of cars from carburetor engines to injection engines with an increase in power and quality characteristics.

Below you can see what a DAAZ gas pump looks like:

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DAAZ

The PECAR gas pump looks like this:

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Baker

It is structured as follows:

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Fuel pump device

To determine the reason for the failure of the fuel pump, you can use several operations related to checking the functionality without removing it from the car.

The fuel pump does not supply fuel to the vehicle systems:

  1. We check the presence of fuel in the gas tank. It is recommended to operate the car with at least half the tank and with the obligatory use of the entire set of filters that reduce the effect of small particles on the fuel pump parts.
  2. We check the efficiency of the fuel filters, if necessary, we replace them with new ones.
  3. We purge and clean the piping system, removing deposits of small particles.

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Check fuel filters

The main reasons for the failure of the fuel pump can be:

  1. Diaphragm damage with leakage.
  2. Loss of spring stiffness and performance.
  3. Clogged valves due to accumulation of dirt.
  4. Loss of filter capacity due to accumulation of contaminants.
  5. Violation of the tightness of the pump circuit with leakage of gasoline and oil.
  6. Refusal in work due to the development of the resource of the pump components.

You can see how the DAAZ gas pump works in the following diagram:

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The internal structure of the fuel pump

To determine the performance of the pump, it is necessary to conduct its external inspection. The top cover must be installed without skewing and fit snugly against the body. The strainer must be installed level and ensure the tightness of the device, preventing leakage at the points of connection and fastening with bolts.

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DAAZ scheme

Next, you need to set the pusher to the operating position, for this, using the handle, the engine is turned by 1 revolution. The stem and eccentric will be positioned to allow manual fuel priming.

An efficient pump, when pumping, pumps gasoline without air. If a mixture of gasoline and air appears in the system, it is necessary to remove the pump and repair it with the elimination of defects. To repair the pump, you must purchase a repair kit, which includes all the necessary spare parts.

In the event of a malfunction of the fuel system, a smell of gasoline appears in the passenger compartment, the cause may be damage to the diaphragm of the fuel pump or stripped thread of fasteners. Fuel leakage is also possible due to incorrect fitting of the union.

The appearance of oily smudges on the bottom of the casing is usually caused by the failure of the lower diaphragm lobe or leakage along the mounting rod in the pump drive.

The diaphragm design consists of a stem, a plastic spacer and three blades. The upper petals supply fuel to the engine, while the lower petal cuts oil from the cylinder block, as well as from the ingress of gasoline in the event of a diaphragm failure. Together with the diaphragm, a return spring works, which also fails, which interrupts the fuel supply through the system (in automatic and manual modes). In some cases, it is possible that the rod of the "foot" of the drive may malfunction (due to displacement to the side), which contributes to the failure of the fuel pump.

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Fuel pump device

Sometimes situations arise when the pump works intermittently, which is usually associated with a failure of the spring.

If it is difficult to start the engine, a possible cause may be wear of the fuel pump valves. With prolonged use of the car, the valves wear out, which leads to failures when starting. After stopping the engine due to loss of tightness, the valves let the fuel through, and it flows into the gas tank, and in order to start the engine again, it takes much longer for the fuel pump to supply fuel to the carburetor.

When the valve plate is worn, the plate changes its position, as a result of which the pump stops working. To eliminate such a defect, the plates began to be equipped with a rod, which prevents its displacement and reversal.

Situations also arise when the overlay from the valve flies off and falls between the valve and the "seat", which leads to the refusal of the fuel pump.

It should also be borne in mind that domestic gasoline pumps use three membranes: two for fuel supply and one for sealing. Currently, there is no shortage of spare parts for any VAZ model. All types of spare parts required for car repair are presented in the trade network, regardless of modification and year of production.

The process of removing and installing the fuel pump is carried out in several operations. The fuel pump is fastened using two studs and nuts with the simultaneous installation of gaskets.

To remove the fuel pump, it is necessary to disconnect the pressure and supply pipelines and unscrew the fastening nuts.

When removing the pump, carefully detach the heat-insulating and sealing gaskets without damaging them.

After the repair, it is necessary to carry out the installation, which has a number of features. First of all, gaskets are installed: sealing, having a thickness of 0.7-0.8 mm, then heat-shielding and insulating gaskets 0.27-0.33 mm. It is necessary to comply with the condition that the pusher is slightly higher than 0.8 mm, if it does not look out, then replace the 0.7-0.8 mm gasket with 0.27-0.33 mm.

If the pusher protrudes above the gaskets by more than 1.3 mm, the 0.7-0.8 mm gasket is replaced with a thicker one, 1.2-1.3 mm thick. It is also necessary to observe the order when a gasket of 0.27–0.33 mm is to be installed between the heat-insulating gasket and the casing.

The set of gaskets between the pump and the cylinder block should allow the tappet to extend by a distance of 0.8–1.3 mm. After installing the fuel pump, it is attached and the gas lines are connected.

The engine is started and the condition and performance of the fuel pump and pipelines are checked for gasoline leaks.

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Disconnect the hoses

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Fittings

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Replacing the fuel pump

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We remove the gas pump

After preliminary diagnostics and determining the cause of the malfunction of the mechanisms, it is necessary to remove the fuel pump and check its performance with an audit of all component parts.

Carrying out the necessary operations carried out when disassembling the pump:

  1. It is necessary to detach the head fastening screws.
  2. The fuel pump head with valves, filter and cover is removed.
  3. The condition of the diaphragm is checked by pressing and rotating 90 ° clockwise or counterclockwise.
  4. The diaphragm and the return spring are removed.
  5. The diaphragm is inspected, if there are defects, the defective parts are replaced with serviceable ones from the repair kit.
  6. Parts are carefully removed from the diaphragm assembly.
  7. A complete audit of all components is done and the assembly is assembled in reverse order.
  8. If it is necessary to replace the valves, the fuel pump head is carefully pressed out of the seat, with the preliminary removal of the punching. Next, a new valve is installed and punching is performed in the seat.
  9. A check of the tightness of the discharge and suction branch pipes of the gasoline pump is carried out.
  10. A complete revision of the head flange fit is carried out in the fastening areas that are exposed to increased stress when the fasteners are tightened. The screws are tightened crosswise using uniform forces.

For photo instructions for disassembling the fuel pump, see below:

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We unscrew the screws and disconnect the case

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Take out the diaphragm assembly and spring, replace the assembly, reposition the old spacer

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Replacing the diaphragm set

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Replacing the strainer and cracked parts

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Flush with gasoline, blow through and collect

The fuel pump of a VAZ 2106 car is the most important unit and provides uninterrupted fuel supply to the carburetor to form a fuel mixture. When traveling long distances, it is necessary to have an additional fuel pump for replacement in the event of a breakdown of the standard pump installed on the car.

The process of repairing a DAAZ fuel pump using a repair kit is shown below: