D24TIC - Injector pump overhaul

John Davies · Sep 5th, 2009, 22:48

Having finally got all our Volvos sorted (o.k., I still have to replace a front wing on my wife's 960) and my rebuilt D24TIC engine up and running, I thought I'd start getting bits together to overhaul a spare injection pump - only to find a total dearth of parts and information!

There is plently of data on the internet about later Bosch pumps, and overhaul kits available but nothing on ours, perhaps because it was primarily an industrial unit.

Anyone know of any overhaul instructions and calibration data, and sources of spare parts? Rapid Parts in the States used to do VW golf/rabbit kits which were o.k. for ours (though you needed two kits as it was only a four cylinder) but they no longer list anything.

Anyone any ideas? (Apart from the wiseacres who will doubtless say leave it to the professionals, I enjoy all mechanical work and hardly ever do so if I can posssibly help it.)

Thanks

John D

jor · Sep 6th, 2009, 00:34

I think you should ask Tom Bryant for help with this if you are determined to do it yourself, he would probably advise against doing it in the first place. He would at least tell you where to get the parts as he offers a rebuild service. There's a thread on the topic on the d24 list and it's current. There's something on Bosch pumps on the Australian Land Rover forums, possibly generic.

jor

John Davies · Sep 6th, 2009, 00:42

Thanks for this, and yes, I'll try Tom. Just wondered if there was anything closer to hand.

Have tried the Landrover site but the pump seems too new.

Amazing isn't it? We think of the US as being a throw away society and yet the number of times we have to look accross the pond to keep our old nails on the road is quite incredible - they seem far more willing than us Brits to get their hands dirty and keep something old on the road by reconditioning their own stuff.

Perhaps it is just that their population is four times the size!

Regards

John D

MRDART · Sep 6th, 2009, 10:29

I saw a chinese website dealing with dieselpump spares what parts do you need?? there is supposed to be a 11mm pumphead assy available that is intended for the dodge /cummins engine. More fuel can´t be wrong can it??
Anyway bosch should be able to supply all the parts you need however it may cost a bit...
I was lucky enough to browse through the swedish advertising page called blocket where a guy had a brand new bosch pump... I bought it instantly....
I think he has one more if you are interested... he wanted about 500 pounds for one pump....

jor · Sep 6th, 2009, 12:49

I don't think it will be of much use, but presumably if a V.A.G. workshop manual booklet on the diesel injection and glowplug system exists for the VW Polo diesel (1.4L), then somewhere on the planet there is one for the LT 25, 35, or 45 directly applicable to your cars.
I got it thinking it was something else. It should give you some idea of general principles and of course those special tools required, let me know if you would like a copy.

jor

Laney760 · Sep 7th, 2009, 17:35

This seller on Ebay reakons he has the right VW Diesel Bosch injector pump rebuild kit for most pumps, you have to give him your 10 digit pump number

http://cgi.ebay.com/ebaymotors/VW-Di...Q5fAccessories

jor · Sep 9th, 2009, 00:10

Here's a link to a step by step of a Bosch pump rebuild.
If this doesn't put you off the idea nothing will..

http://www.vwdieselparts.com/forum/v...epve+stripdown

jor

John Davies · Sep 9th, 2009, 22:30

Thanks for this Jor - very helpful indeed, not least in terms of diagnosis. The main problem seems to be that any real wear on the piston or body and you are up the creek. Seals replacement however should be a possibility.

Will let you know how I get on.

Regards

John

Sep 5th, 2009, 22:48	#1
John Davies VOC Member Last Online: Sep 26th, 2015 22:56 Join Date: Dec 2002 Location: Walsall	Injector pump overhaul Having finally got all our Volvos sorted (o.k., I still have to replace a front wing on my wife's 960) and my rebuilt D24TIC engine up and running, I thought I'd start getting bits together to overhaul a spare injection pump - only to find a total dearth of parts and information! There is plently of data on the internet about later Bosch pumps, and overhaul kits available but nothing on ours, perhaps because it was primarily an industrial unit. Anyone know of any overhaul instructions and calibration data, and sources of spare parts? Rapid Parts in the States used to do VW golf/rabbit kits which were o.k. for ours (though you needed two kits as it was only a four cylinder) but they no longer list anything. Anyone any ideas? (Apart from the wiseacres who will doubtless say leave it to the professionals, I enjoy all mechanical work and hardly ever do so if I can posssibly help it.) Thanks John D __________________ Volvo 760 GLE turbodiesel estate 1989 (auto). Ford Mondeo 2001 mk. 3 Ghia X petrol estate. Austin A60 Cambridge 1966 (auto) . Austin A60 Cambridge 1967 (manual) undergoing restoration. Last edited by John Davies; Sep 6th, 2009 at 00:45.

Sep 6th, 2009, 00:34	#2
jor VOC 20573 Last Online: Jul 10th, 2023 22:14 Join Date: Mar 2007 Location: wembley	I think you should ask Tom Bryant for help with this if you are determined to do it yourself, he would probably advise against doing it in the first place. He would at least tell you where to get the parts as he offers a rebuild service. There's a thread on the topic on the d24 list and it's current. There's something on Bosch pumps on the Australian Land Rover forums, possibly generic. jor __________________ Volvo 940 SE 1994 D24Tic. BMW C1 85 mpg

Sep 6th, 2009, 00:42	#3
John Davies VOC Member Last Online: Sep 26th, 2015 22:56 Join Date: Dec 2002 Location: Walsall	Thanks for this, and yes, I'll try Tom. Just wondered if there was anything closer to hand. Have tried the Landrover site but the pump seems too new. Amazing isn't it? We think of the US as being a throw away society and yet the number of times we have to look accross the pond to keep our old nails on the road is quite incredible - they seem far more willing than us Brits to get their hands dirty and keep something old on the road by reconditioning their own stuff. Perhaps it is just that their population is four times the size! Regards John D __________________ Volvo 760 GLE turbodiesel estate 1989 (auto). Ford Mondeo 2001 mk. 3 Ghia X petrol estate. Austin A60 Cambridge 1966 (auto) . Austin A60 Cambridge 1967 (manual) undergoing restoration. Last edited by John Davies; Sep 6th, 2009 at 00:45.

Sep 6th, 2009, 12:49	#5
jor VOC 20573 Last Online: Jul 10th, 2023 22:14 Join Date: Mar 2007 Location: wembley	I don't think it will be of much use, but presumably if a V.A.G. workshop manual booklet on the diesel injection and glowplug system exists for the VW Polo diesel (1.4L), then somewhere on the planet there is one for the LT 25, 35, or 45 directly applicable to your cars. I got it thinking it was something else. It should give you some idea of general principles and of course those special tools required, let me know if you would like a copy. jor __________________ Volvo 940 SE 1994 D24Tic. BMW C1 85 mpg

Sep 7th, 2009, 17:35	#6
Laney760 VOC Member Last Online: Mar 18th, 2024 12:17 Join Date: Jul 2008 Location: Henley on Thames	This seller on Ebay reakons he has the right VW Diesel Bosch injector pump rebuild kit for most pumps, you have to give him your 10 digit pump number http://cgi.ebay.com/ebaymotors/VW-Di...Q5fAccessories __________________ [IMG]Volvo2 by Strider'swoman, on Flickr[/IMG] Current '96 945 2.3 lpt - Aurigas, tailgate spoiler, sports grille, lpg fuelled Previous '88 764 TD, '92 945 TD, '88 745, '81 244 DL

Sep 6th, 2009, 10:29	#4
MRDART Junior Member Last Online: Jan 19th, 2010 08:40 Join Date: May 2009 Location: Tomelilla	I saw a chinese website dealing with dieselpump spares what parts do you need?? there is supposed to be a 11mm pumphead assy available that is intended for the dodge /cummins engine. More fuel can´t be wrong can it?? Anyway bosch should be able to supply all the parts you need however it may cost a bit... I was lucky enough to browse through the swedish advertising page called blocket where a guy had a brand new bosch pump... I bought it instantly.... I think he has one more if you are interested... he wanted about 500 pounds for one pump....

Sep 9th, 2009, 00:10	#7
jor VOC 20573 Last Online: Jul 10th, 2023 22:14 Join Date: Mar 2007 Location: wembley	Here's a link to a step by step of a Bosch pump rebuild. If this doesn't put you off the idea nothing will.. http://www.vwdieselparts.com/forum/v...epve+stripdown jor __________________ Volvo 940 SE 1994 D24Tic. BMW C1 85 mpg

Sep 9th, 2009, 22:30	#8
John Davies VOC Member Last Online: Sep 26th, 2015 22:56 Join Date: Dec 2002 Location: Walsall	Thanks for this Jor - very helpful indeed, not least in terms of diagnosis. The main problem seems to be that any real wear on the piston or body and you are up the creek. Seals replacement however should be a possibility. Will let you know how I get on. Regards John __________________ Volvo 760 GLE turbodiesel estate 1989 (auto). Ford Mondeo 2001 mk. 3 Ghia X petrol estate. Austin A60 Cambridge 1966 (auto) . Austin A60 Cambridge 1967 (manual) undergoing restoration.

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