A frozen Injection pump Fuel Rack, what to do I remember MJ Mc. Carroll telling me about the folks who worked on fuel injection pumps in his part of the Midwest, Theyd pull down the shades before they worked on a pump, it was their bread and butter, and they didnt want you knowing how they did it. Bridge. Below might lie some trade secrets, and this pump is so similar to all the rest No doubt, a frozen pump is about as useless as a washed out bridge, but if you know a few tricks, you might fix it in less than an hour. On the other hand, you can apply just a little too much pressure to that rack, and youll need a box of parts to fix it, if you can find them. It wasnt that long ago that a Friend pulled a brand new diesel engine from a box and attempted to start it, he lubed it, fueled it, primed it, and no go. So for MegaSquirtII or MicroSquirt, entering a larger VE in the table makes that point richer, and a smaller number makes that point leaner. Arion Af 2000 Manual. Good day Im trying to set the timing on my 96 1. TD aaz. its from a canadian model mex Jetta. Injector Pump is sloted and not the Pump, how do you. Before you start any hardware mods please read this entire manual and the Software Manual, available HERE. For other MS1 Extra Manuals please. See GenBoardManualEcuEcTen for EC10 connector from VEMS ECU not to be confused with the EC10 between GenBoardManualMainWiringDiagrams. Generation Ram Diesel Power Increase 1989 through 1993 Models with the Bosch VE injector pump. F3pcsr5trzE/maxresdefault.jpg' alt='Bosch Ve Injector Pump Manual' title='Bosch Ve Injector Pump Manual' />I welcomed him to the club, and told him how common this is, theres a video on the georgeutterpower You. Tube pages showing a method to verify rack is free  on the Yanmar and  Yanmar clones when you find the engine wont start, dont pick up a hammer Read to the end, it may save you days and dollars, it has others. The probability of seeing a frozen rack increases if you live in areas with a lot of humidity, and where the air temperature can rapidally rise leaving metal surfaces a lot cooler than the surrounding air. If you live in the Desert, youll see troubles like this less often. There are other causes, but a microscopic amount of moisture between the plunger and the barrel is a leading cause. Keeping your pump full of clean dry fuel is key If theyre left in the shipping box, theres a chance they are less protected from moisture. Injection pumps found in small engines are normally pretty simple, but never confuse  simple with a lack of precision, because any pump that works well is a precision piece of equipment, with tight clearances, so when you take a pump apart, you best make every effort to find a clean and well lighted area to work. Ill assume you know that just soaking a part doesnt make it clean, a scrubbing action  is normally required on small parts, and those who have experience with ultrasonic parts cleaners learn this. YANDET2.JPG' alt='Bosch Ve Injector Pump Manual' title='Bosch Ve Injector Pump Manual' />Follow up the scrub with a rinse in gasoline or similar and then dry the parts and drop them in a small jar of new diesel fuel till you assemble them. I like to work on white printer paper, I have no idea what the pros do. Taking the pump apart is usually a lot more difficult when the rack is stuck, knowing not to apply a lot of force to the rack is the first thing to know, the second is to learn that the barrel normally drops in from the top of the pump, and the plunger is put in from the bottom, so when the plunger becomes seized inside the barrel, theres a disassembly problem. I have written other articles, most are on the utterpower CD including disassembly and re assembly of a common Lister Style 61 pump, youll be surprised how similar they all are, and at the center of these pumps are two very common elements that make them work. One element is a plunger like a piston, and a barrel, like a cylinder, but theres an additional bit of near magic, and that is a helix cut up the side of the plunger, this is cut like the stripe on a barber pole, a spiral like groove. Above Plunger in foreground, and Barrel behind it. Notice the helix cut spiral around the plunger, also note that piece down a bit from the left end, this tang slips into a slot on the ring gear and it turns the plunger and adjusts the position of the helix to alter the pump stroke, amount of fuel delivered per stroke of the pump. The rack drives the ring gear. If you follow along so far, you can see that a stuck plunger will result in a frozen rack, but it may not be all that obvious that any banging or hammering on the rack is loaded onto a single set of teeth on the rack and ring, and permanent damage is normally the result of forcing the rack. Above  Heres the ring gear around the plunger end, you can see that tang is inside the ring gear slot. Garmin Topo France V3. Visualize the rack seen to the left engaging the ring gear, and note just how few teeth will take any pounding you do on the rack, the normal result are teeth broken clean off the ring gear. The location of this helix grove has everything to do with the pump stroke, and the amount of fuel delivered per stroke. The rack turns the ring that rotates the plunger. The rack of course is normally tied by linkage to the governor, and depending on the engine design, all or part of the complete fuel control and governor system RPM control can hidden from your view. Reading an article like this can be helpful, but only hands on experience can transfer the complete picture to you. Ill give you more of an example here. My DIYer friend who called me about this pump asked me how to take it apart I told him, let the whole unit set in warm penetrate for a while, and diesel fuel works pretty good for that. After you run out of patience waiting for the pump to loosen up,  you use kinetic energy to take the pump apart. Remember that plunger is normally stuck fast inside the barrel, and we need it to come out. Heres where the knowledge transfer gets cloudy, Just how do you apply this kinetic energy and how much My answer is you need know how the components go together, and you need apply the kinetic force in line with the plunger, and from the end that will move the plunger in the right direction. But first above I talked about two main elements inside a pump and mentioned only one. The first was the plunger and barrel, the second is the delivery valve that sits right on top of the barrel end that is precision machined flat. The delivery valve is two pieces, the valves machined flat surface sits right on top of the Barrels flat top, and the smaller valve piece is found in the center, and is hidden by the large flange nut that the high pressure line attaches to. One thing you need to know, that copper composite washer gets crushed a bit and holds the valve body in tight, and about the only way you can remove it IS with kinetic energy. Put a leather glove on, and hold the injection pump body tight, and lower the body flat on the valve end of the pump body. A really good smack might be necessary to loosen the washer and the valve body behind it. Once you have removed the delivery valve, you will be able to see the plunger inside the barrel, is it full of mud, rust, or whatNext is to assure you have removed as much as possible from the plunger side of the pump, this is the side that the injection pump cam follower runs on, youll have a roller, a pin, a retainer clip, and possibly more youll strip off, and put into your parts to be cleaned bin. Youll see this part on the left when you look at the last part you couldnt disassemble from the cam follower end. Theres a spring, and possibly a spacer or cap, behind this part, and the reason you werent able to remove it, is because theres a slot that locks the end of the plunger and this part together With this understanding, you now check your pump for loose parts again, put your glove on again, and hold the pump with the plunger end cam follower end down.