Now i’m scared.

[Shvegel]

I decided to rebuild my fuel injection pump because my car was apart and I like to learn new things.  I bought the manual out of England and printed a Bosch one I found online  It’s been a very long time since something mechanical has scared me.  This is scary but I am enjoying it.  Luckily I own a lathe so whenever I get stumped i can make a tool to do whatever I need to.  There are a lot of parts in there and even tiny mistakes could be really bad. I have a couple spare pumps for reference (I wouldn’t do it without one) and parts as well as a couple friends with flow benches who can help with the final dialing in.

[Pawel66]

I hope you will have no parts left when you finish assembling it back together....

Unless it works with fewer parts when you're done!

[cabrioletturbo]

Shvegel, please DO document every step of re-assembly. it would be a great addition to the Tech Manual.
Thanks in advance.

[Shvegel]

Igor,
I am not sure documenting it really has any value.  The book I bought from www.911MFI.com covers it fairly well but without special tools, spare parts, a flow bench and a really tough to get spec sheet for your specific pump you can run into trouble in a hurry.  I am figuring out some things I didn’t know like if you have a stuck piston from sitting even if you free it up you can throw the mixture slightly off until the pump is taken apart. 

[Rolf-Dieter ✝︎]

If you Google "fuel injection pump Pagoda" you will find several images and photos with descriptions etc that might help you out. Then we hope you took plenty of photos on disassembly ...

Good luck!

Dieter

[mbzse]

.../...if you have a stuck piston from sitting even if you free it up you can throw the mixture slightly off until the pump is taken apart

The six pump elements in the Pagoda FI pump are high precision parts. The fit is a microscopic 2 microns...!  The slightest imperfection on the plunger surfaces will cause the pump element to give erratic output and also fuel leakage (internal in pump, dilutes oil).
When these pumps are professionally assembled, it is done immersed in liquid to keep out dust and any minute dirt particles.

[Benz Dr.]

I'm going to STRONGLY advise that nothing concerning how to rebuild injection pumps but put in the tech manual. Aside from external adjustments which can be done without too much effort by most owners, IP rebuilding is a dead end for just about everyone here. However, if people want to put this on the site and introduce someone to a fool's errand, don't let me stop you.

No offense to those who have tried this and somehow managed to get through it but this not the kind of info that we need to post here. One mistake could damage your pump and worse than that, your engine. Your mileage may vary.... 

[Shvegel]

What Dan said times 2.  I have spent almost as much as I would have having someone do it to get set up.  I did it for fun and for the learning process.  I would never even think about touching any one else's pump even for pay there just isn't enough in it to pay for a new engine.  Getting the pump apart was a task and if I couldn't walk downstairs and make tools on my lathe I would have doubtless destroyed the pump on two different occasions.

[66andBlue]

Re: Now i’m scared.
Pat,
my hunch is you just want to have a real horrific Halloween scare! 

[Tom in seattle]

Let's hope bravery prevails, intellect will help. I'm glad I spent the money.

[doitwright]

I understand the concern expressed here about exploring uncharted waters and how it pertains to potential disaster but I must say I am very interested to hear what becomes of Shvegel's project. He seems to have the resources and understands the risks. He also has a backup plan and there are fuel injection pump rebuilders that can always bail him out if necessary. This reminds me of the time I was skiing in Utah and I asked a 10 year old what it was like to ski in the bowls. He said "Awe man, it's great. I'm going there myself right now". Because our egos got the better of us, my friends and I followed him to the top (despite the skull and cross-bones graphic on the warning sign at the lift). It took us an hour and a half to get out of there and it was a miracle we were not discovered until the following spring.

Being scared or nervous makes us more focused. Shvegel, from what you have explained so far, I think you can pull it off. The first one always takes longer.

Good luck.

[Shvegel]

I do my best work when I am scared.  2 or 3 pumps in I start to slack off.  Back together.  Time to put it away until I get back in December.

[cabrioletturbo]

Looking pretty...

[Pawel66]

No parts left? 

[Shvegel]

No parts left.  I was home this weekend and I hooked it up to a drill and ran it.  pumping fine on all 6 cylinders and the governor seems to be working well.  I am going to finish my test stand in December (Hopefully) and set it up myself then send it off to Hans at H and R for the final exam to see how I did.