Rebuilding a Bosch VE injector pump (mitsubishi ZEXEL pump)

[tortron]

Come with me as i work on an L300 mitsubishi van with 4D56 engine and Zexel ( style of Bosch VE) injector pump.


The problem - fuel leak. Appears to be from rear of pump in a few places around the distributor block (square section on the back)

Probably just a seal/Oring has shrunk over time. Pump is otherwise fine, no noises so the plunger is probably ok.

This is the information i am following


https://www.youtube.com/watch?v=SqBlqdeP3uE


https://www.youtube.com/watch?v=_01gEg2ZMwg


https://www.youtube.com/watch?v=RkDsEQx82do


https://www.youtube.com/watch?v=TNVLw4WRJdU


http://www.delica.ca/manuals/L-400%20Manuals%20&%20Plans/fuel_system.pdf



https://www.youtube.com/watch?v=9S4DX1k3F_I

[tortron]

removing the pump




https://www.youtube.com/watch?v=d0HmtraNKm8

Next, dismantling the pump

[tortron]

http://www.mightyram50.net/vbulletin/attachment.php?attachmentid=26190&stc=1

Diagram and torque specs

[geezer101]

Nice write up :thumbup:

[tortron]

https://www.youtube.com/watch?v=Fs52MfiZmpY

[tortron]

My DIY timing tool

i used an m8 1.0 bolt. Drilled through with a 4mm drill bit
some 3mm rod (titanium because thats what i had) and a bicycle cable sheath ferrule heated and pressed onto one end
some 10mm diam stainless steel tube. silver soldered to the bolt

Then made a clamp out of some scrap 1/2" plate and an allen bolt i had laying around.

Dial gauge is just a cheap aliexpress one, but does the job well enough for my stuff (already had it for my bicycle wheel truing stand)

http://www.mightyram50.net/vbulletin/attachment.php?attachmentid=26193&stc=1
http://www.mightyram50.net/vbulletin/attachment.php?attachmentid=26195&stc=1
http://www.mightyram50.net/vbulletin/attachment.php?attachmentid=26196&stc=1
http://www.mightyram50.net/vbulletin/attachment.php?attachmentid=26194&stc=1



https://www.youtube.com/watch?v=YbVmTxX0fKQ

[camoit]

Great thread so far. Keep it up.

[tortron]

https://www.youtube.com/watch?v=VgcBmifwh0Q


Unfortunately the last half of my video of this got corrupted on the card, but you should have no problems following along with the official Bosch video

[Sandrailstudent]

This is still a super helpful thread. Thanks for posting it and all of the contributions.