1hz injector pump rebuild

[3DB Senior Member Find all posts View Profile Close 3DB]

Re: 1hz injector pump rebuild

Some good information coming out in this thread. We need someone with a flowchart builder to put it all in as a reference sticky to save it all being written out again in a few weeks time when the next person has this problem.

It makes a lot of sense to start with the simplest, most obvious & cheapest troubleshooting techniques first and progress to the harder, more expensive ones if they don't work.

At this point hunting for that filter screen makes a lot of sense and it will be the next thing I investigate if my problem comes back again. My Zexel IP does not have one under the inlet banjo. I never found one when I was fiddling around a couple of years ago to try to increase the power, but I can't remember whether I removed the cut-off solenoid.

Anyway, it may be worth consulting Capataincademan as he is the other guy with a 1HZ that immediately comes to mind and it seems like he would know the location of that screen on your vehicle. Hopefully it is easy to get at without removing the IP from the vehicle or having to remove other stuff.

Regarding the acetone flush - yes, I used my Facet pump to do that with the engine off. I don't know how your engine would go if you pumped it at high concentration through the injectors while running, but I think I got a least a bit burned through mine when I re-started. I cannot say that the acetone won't kill your Facet pump either. Mine died before I finished a full 500 mL flush, but it seems like it was probably already on its last legs.

[3DB Senior Member Find all posts View Profile Close 3DB]

Re: 1hz injector pump rebuild

Sorry - completely overlooked the air in return line issue in my response above.

If if you remove the Facet pump from the equation and run the engine do you still get air in the return line?

[Tony From West Oz Vice Chairperson of WARFA Find all posts View Profile Close Tony From West Oz]

Re: 1hz injector pump rebuild

You said previously that adding the Facet fuel pump restored engine performance - for a while.
That indicates that the problem lies within the IP.
You have a few of choices:
1. Have the pump cleaned and checked, or
2. Source a second hand pump to suit your engine from a wreckers.
3. Have a go at dismantling and cleaning your IP yourself.

[farmerpete Junior Member Find all posts View Profile Close farmerpete]

Re: 1hz injector pump rebuild

Qwarla ... you the man !!!! and Tilly , 3DB etc

I used google pictures and went to the web pages of multo problems involving no power / smoking 1hz engines
So one bloke did what I did...checked the filter screen in the injector pump inlet and couldn't see one but he went down in the hole about 60 mm with a piece of wire with a hook on the end and found one
So did I... and found one. I did look at some stage previously but didn't really know what I was looking for
Pulled it out with a twisted picky thing and blocked to buggery. Its built of delicate fine s/s mesh
Cleaned out with SCA degreasing spray and a .22 calibre soft nylon barrel brush. It had no plastic base so left crap at bottom of hole.
Fortunately the fuel intake down that hole is about 2 cm off the bottom so sucked out out the contents thru a small plastic hose by mouth.
Back flushed with gravity thru the return line with diesel to make sure its all clean and sucked out again
Back together with the external fuel tank on the ladder and no facet pump attached
No bubbles ....
4500 rpm and black smoke
...that made for a big smile. Didn't check for air bubbles in the return line.
Still need to check for air leaks as I put the fuel system back together to find what is allowing air in
I took some photos will post soon
Thanks to ewes all for your inputs.
I just realised the engine probably hasn't revved to max for 7 or 8 years because this was developing slowly

[Qwarla Senior Member Find all posts View Profile Close Qwarla]

Re: 1hz injector pump rebuild

Qwarla ... you the man !!!! and Tilly , 3DB etc

4500 rpm and black smoke

I bet that gave you that 'warm n fuzzy feeling'.
Nothing better than poking about and fixing the problem yourself and saving yourself a packet.
Big scary things them IPs. But if it's stuffed, playing with it won't do any more damage and sometimes ya just get lucky and fix it.

Somewhere along the way your filters must have let some crud slip past. This can happen bio melts all the glue holding the element together, or just a small part of the glue and makes for a small hole.
But now you know where to look next time.

Good work.

[farmerpete Junior Member Find all posts View Profile Close farmerpete]

Re: 1hz injector pump rebuild

The cigarette sized filter

[Dr Mark Senior Member Find all posts View Profile Close Dr Mark]

Re: 1hz injector pump rebuild

Farmerpete. I am not sure that your engine behaves the same as the 1HT engine, but if it does:
Remove the facet pump from the fuel delivery line. It cannot pass enough fuel for that engine. It pumps a lot more fuel than the engine needs and the restriction may cause the symptoms you have.
If you need a primer pump put it in the return line to suck the fuel thru the filter and IP. This could cause issues with the IP internal pressures though.
If running on veggie oil increase the fuel delivery line to 1/2"ID to further minimise restriction.
Check posts by Tim HJ61

Hope this helps,
Tony

Not sure this is right. Years ago my fisrt BD car was a 1HZ. After a few months the IP karked it and I sent it to a mob in Qld to get it rebuilt with Viton seals. When I got it back it didn't quite run right. It behaved as though I didn't have full throttle travel, and consequently it was flat out at 100kmh. I thought about sending it back, but this involved a fair bit of mucking around, so I thought I'd try fitting a Facet pump to see what happened. Bingo - problem solved, and it ran perfectly.

If you're looking for a bio friendly IP rebuilder, there's a mob in Picton NSW (whose name escapes me at the moment), or if you wanted to send it to WA you will find Total Fuel Injection in Balcatta will happily rebuild a BD compatible pump for you, and they are the cheapest in Perth

[Tony From West Oz Vice Chairperson of WARFA Find all posts View Profile Close Tony From West Oz]

Re: 1hz injector pump rebuild

Mark,
Did you fix the problem causing the poor performance or just continue with your work around?
Tony

[Dr Mark Senior Member Find all posts View Profile Close Dr Mark]

Re: 1hz injector pump rebuild

I just left it as it was. It was running fine so if it ain't broke don't fix it. But it meant that I had to carry a spare pump with me just in case

[farmerpete Junior Member Find all posts View Profile Close farmerpete]

Re: 1hz injector pump rebuild

Tony
The info in this thread is very relevant to another thread in Making Biodiesel titled '1HZ wont rev heaps of smoke'. That thread has had 12000 views
Perhaps the info in this thread and that other thread should be somehow combined?
Cheers
ps O how the om606 goes compared to the 603.Its so much fun to drive .New plastic fuel hoses already.

[mathuranatha Biofuels Forum Newbie Find all posts View Profile Close mathuranatha]

Re: 1hz injector pump rebuild

It looks to me that you are trying to convince yourself your injectors are stuffed.
Picture this-
IP is sending an amount of fuel to each injector. It can go two places.
1. Into the engine and be burnt producing power.
2. Out the overflow tube and return to the fuel tank.

Now you have no, or very little overflow and very low on power. What does this suggest to you?
To me it says you are not getting enough fuel delivered to your injectors.
If you have had the engine running as described, everything on your vehicle has been bypassed except the IP. So the problem has to be within the IP.

The vein pump will not be visible through the return banjo bolt hole. It's usually down the front near where the IP bolts to the engine.
The fact that the screen in this hole was clogged with crud must tell you something.
it tells me that your filter system has had a failure and let crud into your IP.
If you study the diagrams further back up this thread you will discover something that may help you. Marked in big blue letters.
On most IPs there is a sintered filter between the IP pumps body and the high pressure head. Sometimes under the fuel shut off solenoid.

All the fuel that gets sent to the injectors has to pass through this filter.
Since there is/was crud in your IP it is a fair bet this other filter copped a fair bit as well and is very restricted.

If I was a gambling man I'd put up $20.00 saying this is your problem.

you seem a pretty knowledgable bloke , wonder if you know if the L or 2L [not sure which I have ] Hilux motors from the 80s have an intrnal screen in the IP and if so where ? :-) thanks :-)