Rebuilding a Bosch VE injector pump (mitsubishi ZEXEL pump)

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%2...uel_system.pdf


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

removing the pump



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

Next, dismantling the pump

http://www.mightyram50.net/vbulletin...id=26190&stc=1

Diagram and torque specs

Nice write up :thumbup:

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

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...id=26193&stc=1
http://www.mightyram50.net/vbulletin...id=26195&stc=1
http://www.mightyram50.net/vbulletin...id=26196&stc=1
http://www.mightyram50.net/vbulletin...id=26194&stc=1


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

Great thread so far. Keep it up.

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

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