Complete Delica Injection Pump rebuild from top to bottom

[jessef]

Since owning my Pajero's and Delica (Granola), I've looked for ways to either maintain or improve on it's reliability and functionality.

Most Delica/Pajero owners I've spoken with about IP's did not know the difference between a typical rebuild (seals) and a pump overhaul (full rebuild). I thought I would bring this to you guys' attention

Mechanically, the fuel Injection Pump (IP) is robust and almost takes care of itself as far as maintenance is concerned.

That is unless it has been sitting unused for extended periods of time. The seals begin break down and the linkages/solenoid/components may seize for fail.

The IP is the heart of our Delica's and seeping seals, seized sleeves, etc... lead to problems down the road.


To resolve this, there are a few different approaches.

1. Ignore it

2. Use seal conditioner and try to revive the seal compound so that it remains soft and expands (no leaks)

3. Typical Rebuild - Replace the seals (no leaks)

4. Pump overhaul/Complete Rebuild - Rebuild the IP and replace the seals (no leaks + very tuned IP)

I opted for #4 and had the entire IP torn down, worn internal parts replaced, solenoid replaced, seals replaced and then bench tested (IP machine tested) for accuracy up to Mitsubishi specifications.

The end result is a very clean burning, smooth idle/speed, increase in power and better mileage.

I handed my Delica over to Mardy and he had the IP rebuilt.

I have had the pleasure of dealing with Mardy even before I owned a Delica.

I firmly recommend this IP rebuild to anyone looking to keep their Delica's for the long term.

Any q's. I'll try to answer (have diesel mechanic / and IP specialist at my fingertips for info).

Jesse

**NOTE** Not all Delica's have the same Injection pump's.

Some Exceed's differ from Super Exceed's and Chamonix models (different throttle linkage ... a/c thread length,etc...)

[bae146]

I was going to have Mardy do mine this summer but I was unsure that it would be able to be done in time. That and I had spent to much money in bc on vacation already. Maybe will get it done around Christmas when I am out again.... I am not sure I really need it but I am a stickler for reliability so I will probably get it done anyway.

[PHIL]

Would it be bad form to ask how much one would expect for a full IP overhaul? Are we talking a grand, or more, or less? Just thinking ahead... a buddy of mine had the pump done on his Landcruiser (60 series) and paid large for it...

[39Ronin]

Jesse, Did Mardy use CVI or another shop to do the work?

I know typical injection specialist shops rip you off to the tune of $2,000 or so, plus re and re. I had the pleasure of having my Townace pump rebuilt a few years ago and all in it was $2800. So I guess the three majors in our vehicle are the IP, transmission and engine.

[after oil]

To resolve this, there are a few different approaches.

1. Ignore it

2. Use seal conditioner and try to revive the seal compound so that it remains soft and expands (no leaks)

3. Typical Rebuild - Replace the seals (no leaks)

4. Pump overhaul/Complete Rebuild - Rebuild the IP and replace the seals (no leaks + very tuned IP)

here is number 5:
if you have a leaky pump, try running 50/50 wvo and diesel. i know of two very leaky pumps so far that never leaked after this fix. one pump i know went from a fast stream of diesel to no leak at all!
almost miraculous. remember though that 50/50 is only good for summer!

[jessef]

Mine was leaking (just a touch) and it was also blowing smoke pretty bad on acceleration/startup. Also shaking a lot on idle.

I had CVI clean the injectors, Delica-Tune, new filters, oil change, timing set, etc... but all of the above still persisted.

In come Mardy and the injection pump guys.

They said that just replacing the seals won't cure my problems.

Problems which I thought were normal on a diesel Delica.

After the IP rebuild, smoke disappeared, shaking at idle disappeared, power increased.

here is number 5:
if you have a leaky pump, try running 50/50 wvo and diesel. i know of two very leaky pumps so far that never leaked after this fix. one pump i know went from a fast stream of diesel to no leak at all!
almost miraculous. remember though that 50/50 is only good for summer!

That would be #2. the WVO mix acts as a conditioner.

Jesse, Did Mardy use CVI or another shop to do the work?

I know typical injection specialist shops rip you off to the tune of $2,000 or so, plus re and re. I had the pleasure of having my Townace pump rebuilt a few years ago and all in it was $2800. So I guess the three majors in our vehicle are the IP, transmission and engine.

Mine was a test bed.

It wasn't cheap but hands down, the biggest change on my Delica.

I'll let Mardy price it out for a normal Delica.

It was an injection-specialized shop that did the rebuild.

They tear down the IP and replace any internal/external components that don't meet the manufacturer specs and/or are not working properly. Then it's re-assembled back to original specs and then they have some special machines that they use to calibrate and adjust everything inside/outside the pump. It's a pretty neat/specialized process.

[windsnob54]

Coming from the VW diesel world I know there are a lot of people having their pumps modded for significant gains in both economy and power. Things like the governor mod, the boost pin, cam plate, plunger size etc. check out vwdiesel.net and serch "giles" and see what this guy is said to do to pumps.

I know the pumps are very similar. Wondering if anyone has any insight into how these modes relate to the pumps in our deli's.

Martin

[jessef]

Coming from the VW diesel world I know there are a lot of people having their pumps modded for significant gains in both economy and power. Things like the governor mod, the boost pin, cam plate, plunger size etc. check out vwdiesel.net and serch "giles" and see what this guy is said to do to pumps.

I know the pumps are very similar. Wondering if anyone has any insight into how these modes relate to the pumps in our deli's.

Martin

Almost identical.

[delicat]

PHIL, I had mine done through Mardy as well and it came under $1000.

[after oil]

here is number 5:
if you have a leaky pump, try running 50/50 wvo and diesel. i know of two very leaky pumps so far that never leaked after this fix. one pump i know went from a fast stream of diesel to no leak at all!
almost miraculous. remember though that 50/50 is only good for summer!

That would be #2. the WVO mix acts as a conditioner.


DUH

[jessef]

Reviving this thread because of more and more Injection pump threads/questions.

Our 4D56 IP bodies share similarities with the Bosch VW IP's.

Many VW's imported from Germany end up having to get an IP overhaul after being driven here as do JDM diesels (landcruisers,etc..)

It's the sulfur diesel quality and stop & go traffic that attributes to most of the IP issues here in Canada.

I've had four IP's rebuilt recently and some VW's in the past. Two with a general rebuild/seals/clean and two with a complete overhaul (sleeve/solenoid/boost pin/cam plate/plunger, etc.. replaced) and recalibrated to manufacturer specifications.

If you notice your IP leaking, it may just need new seals and an internal cleaning.

If you notice you have lack of power and/or excessive smoke and have tried everything under the sun to fix the issues, then you may need an overhaul.

I find explaining this to some people difficult because there is a significant difference between a rebuild and a rebuild.

What ? a rebuild and a rebuild ?

That's right.

You can have you IP rebuilt differently at one service center compared to another.

Normal rebuild - Disassemble, clean, reassemble with new seals, set vehicle timing.

Major rebuild - Disassemble, clean, replace worn internal/external parts, calibrate internal pump timing, reassemble with new seals, set vehicle timing.

There is a big difference between the two.

You will notice/feel it in too ways :

1. your wallet. Normal rebuild 350-800(avg 500) compared to Major rebuild 800-1500(avg 1000)

2. peformance. normal rebuild - less smoke/ no leaking compared to major rebuild - less smoke/better mpg/increase in HP/ no leaking

About as clear as I can slice it.

Most people have work performed on their vehicles based on their wallet and not what the vehicle actually needs.

Given that, a normal rebuild in most cases is fine.

I opt for long term preventative maintenance and refer people to get a major rebuild since it's being pulled out and disassembled anyways.

As for the shop doing the overhaul.

The Delica engine (4D56T) injection pump has the same parts as common VW Bosch injection pumps.

That means that you can take it to any injection / diesel specialist to get it done.

The timing/dial set tool used for this type of injection pump (Mitsu/VW/Bosch) can be bought as well if you plan on setting the timing yourself (ie. set back or advance the timing depending on how you want to tweak it). This is only recommended for 'real' mechanics and not 'DIY' mechanics. 'recommended' being the key word.

Jesse

[thelazybrownfox]

Jesse

The end result is a very clean burning, smooth idle/speed, increase in power and better mileage.

My deli is clean burning but I have to ask what mileage are you getting after the rebuild? Also Is it possible to smooth out a diesel idle?

it would be awesome to improve my mileage and smooth out the idle. I'm happy with the performance?
Wayne

[konadog]

...smooth out the idle.

Have you replaced the motor and tranny mounts? A really bouncy idle can be smoothed out a fair bit with fresh ones

[thelazybrownfox]

That sounds like a good suggestion and my only excuse is laziness. I should get a hand and crawl under while reving the engine up.

Wayne

[jessef]

The mounts play a large part in the rattle-n'-shake at idle.