Lots of adjusting to do on this pump. The first run was just a flush into a 250ml graduated plastic cylinder. I wanted to do this before I installed all the lines to the injectors. The first run was all over the place as you can see by the photos. This will take some time adjusting.
http://forums.pelicanparts.com/uploa...1242680882.jpg

First test run:
http://forums.pelicanparts.com/uploa...1242680900.jpg

Second test run:
http://forums.pelicanparts.com/uploa...1242680914.jpg
A lot of adjusting!!

Plunger installation
 

According to an old reference for the single in line pumps PES..KL.. (ref VDT-WPP 71111 EP dated 4.63)

http://forums.pelicanparts.com/uploa...1242689057.jpg
(C) Robert Bosch GmbH 4.63

A rough translation (anyone with better German is welcome to chime in here !!)

"After pre-setting of the elements (edit:clearance at TDC =OT) (by possible exchange of the cam followers) the piston foot spring becomes strained by rotating the Roller shaft around 360° in the clockwise direction with EFEP 458."

Note this refers to the single in line pump arrangement - all elements rotated in the same direction.

Tool references:
EFEP 458 = tappet clamp for preloading the plunger base spring
EFEP 457 = spring seat gripper for fitting pump plungers with plunger base spring and spring seat
EFEP 76 = plunger gripper for fitting pump plungers without plunger base spring and spring seat (for checking free movement of plunger)

Now, for the Porsche double in line PED..KL.. pumps - the following is taken from the repair instruction VDT-WJP 711/1B Ed.2 Sup 9.67

http://forums.pelicanparts.com/uploa...1242689037.jpg
(C) Robert Bosch GmbH 9.67

Leads me to believe that the rotation is implied by required final orientation of the plunger markings "always visible on the outside of the pump".

Further - I think these springs provide restoring force to the rack - forcing it to the stop position. So it's important to get them all forcing the rack in the same direction - closed....wouldn't be a great outcome to have the pump at WOT fuel delivery as the default position.

Hope this helps, and happy to stand corrected.

Regards
John

Great information John. My plungers are installed correct, with the 3 digit number to the outside. As far as the 360 degree twist of the "piston foot spring", I preloaded 4-5-6 with the twist, but left 1-2-3 with no preload twist. I wanted to see if I could see a difference. The preload seems to be a good idea, but I can't find any information on that procedure for the PED series pumps, only for the PES series as you pointed out. I took some photo's of the flow data sheets I made for the first flow runs on this 2.2 E corroded pump. Photo's below. Hope it makes scene.

Section B is the first series of tests that I'm doing. This is the Bosch test sheet:
http://forums.pelicanparts.com/uploa...1242694000.jpg

Red circles show the target flow and the lowest flow.
http://forums.pelicanparts.com/uploa...1242694024.jpg

After that adjustment was successful, now I have two high flow ones to deal with.
http://forums.pelicanparts.com/uploa...1242694042.jpg

A photo of the test sheet I made up. T1 thru T4 are the average flow totals.
http://forums.pelicanparts.com/uploa...1242694055.jpg

Mark

Makes perfect sense - minimise variance within the group and within the range.

Your careful and methodical approach is not lost on those of us following this thread. Looks like you're well on the way to getting this done - bravo !!

John

+1 This is really good stuff!

I wonder if Mr. Pfister is following this thread.

Hello Mark

you're a bit further than me !:D
here's a 2.4E waiting for dyno test ...
http://forums.pelicanparts.com/uploa...1242760882.jpg

Well organized Philippe. Can you post a picture of your MFI dyno system?

Having problems adjusting the #6 plunger to maintain a consistent flow at low RPM's to high RPM's. Readings at zero throttle @ 400 rpm would only get 7 to 8 ml for #6 and the rest would be at 13-14ml. So I adjusted #6 a few times only to get it up to 8.5ml. Then at a flow test with max throttle @ 2000 rpm numbers 1 - 5 are between 43 - 44.5ml and # 6 is at 52ml. When I adjust # 6 back down for the 2000rpm test then at a zero throttle @ 400rpm its at 5ml and the rest are at 13-14ml.
Recheck the TDC plunger heights and all 6 are in between 0.5 & 0.6mm. So I remembered the problem with all the corrosion on the #5 & 6 plungers and cylinders. I had a difficult time cleaning #6 piston top area.
Wire brushed it to death but still would not slide into the cylinder good. Seemed to bind up halfway in. So I used some very fine grit, 2000 emery paper to clean it up. I spent about 30min cleaning, or should I say sanding that plunger before it would finally slid through free.
http://forums.pelicanparts.com/uploa...1242941384.jpg



Well the problem is that I over did it. I most likely took off all the sharp edges at the top of the plunger and also increased the clearance between the plunger and cylinder. I also cleaned out the cylinder bore. What was I thinking?
http://forums.pelicanparts.com/uploa...1242941651.jpg

Lesson learned. I have another pump that's missing front & side covers so I will dissemble it and get a plunger & cylinder out. I'll start testing again by tomorrow I hope.

John: You needed pictures and measurements of the "piston foot". Hope this will do.

http://forums.pelicanparts.com/uploa...1242949570.jpg

http://forums.pelicanparts.com/uploa...1242949586.jpg


http://forums.pelicanparts.com/uploa...1242949706.jpghttp://forums.pelicanparts.com/uploa...1242949757.jpghttp://forums.pelicanparts.com/uploa...1242949788.jpghttp://forums.pelicanparts.com/uploa...1242949829.jpghttp://forums.pelicanparts.com/uploa...1242949905.jpghttp://forums.pelicanparts.com/uploa...1242949930.jpg
http://forums.pelicanparts.com/uploa...1242949942.jpg

Thanks Mark...perfect

I was thinking of something like this - might need some tweeking on some dimensions

http://forums.pelicanparts.com/uploa...1242959761.jpg

John

well, maybe :D

but it's really an "old school" unit, compared to your professional top looking system ...

I used sometimes, the paste for "breaking in" (not sure for the words ?) valves to remove rust ;)

Looks great John. That's a lot of work on a tool just for installing the plunger and giving the piston foot spring a 360 turn, but I'm sure it will save lots of time. Let me know if you need any other measurements. I have done the plunger instalation two different ways. After installing the plunger I turn the cam follower 360, or after plunger installation I turn the plunger guide 360 then tighten clamp.
Philippe, When I first started the idea of a test stand that's what I was going to use it for, just breaking in the pump and looking for injector performance. But soon I figured it wouldn't much more work to build a complete dyno. Glad I did.

Overkill? probably, but I have small lathe and the time to do it (and I like gadgetry)

Good luck with reassembly and test with the new cylinder & plunger

Thought I would post some pictures of the difference between the early 2.0 - 2.2 plunger and the 2.4 plunger.

The first one is the 2.4 plunger.

http://forums.pelicanparts.com/uploa...1243373460.jpg

This is the 2.0 - 2.2 plunger.

http://forums.pelicanparts.com/uploa...1243373536.jpg

Closeup of the plunger assembly.

http://forums.pelicanparts.com/uploa...1243373604.jpg

And a close up of the spring.
http://forums.pelicanparts.com/uploa...1243373665.jpg

While waiting on the replacement plunger for the 2.2E pump I started on the next pump. This is a 2.4T pump that will be getting a 2.4S Euro space cam installed. As you can see below this pump is very dirty inside.

http://forums.pelicanparts.com/uploa...1243376354.jpg


http://forums.pelicanparts.com/uploa...1243376369.jpg


http://forums.pelicanparts.com/uploa...1243376381.jpg


http://forums.pelicanparts.com/uploa...1243376397.jpg

I was interested in the weights of the flyweights, so after cleaning them up I weighed them. 218.7 grams on one and 220.1 on the other. I marked them so they will get installed back in the same location.

http://forums.pelicanparts.com/uploa...1243376705.jpg

Maybe this might be a good time to remove a few grams so to extend the max RPM / fuel delivery of the pump? http://forums.pelicanparts.com/uploa...1243376885.jpg

Reminder - 5 screws, 4 washers
 

Just a reminder about the intentionally missing washer on reassembly.

From VDT-WJP 711/1B Ed2 Repair Instructions:
"Caution: contrary to the information appearing in the service parts list, no spring washer must be used under the upper fixing screw of the governor housing"

http://forums.pelicanparts.com/uploa...1243575385.jpg

Lightened flyweights
 

Scott might help you with this pursuit....

Holding the flyweights for machining would be an interesting exercise in itself. You'd also be in custom space cam (and spring/setting) territory, given the change in fore/aft movement of the cam with speed.

Certainly an entertaining thought !!! :)

Thanks John. While I was removing the governor body from the pump I noticed the missing washer. I checked another pump and also noticed the washer missing on the upper screw. As you know, that upper screw entails the extra work of removing the lever above the space cam with all the mini spacers, clips and spring. That 's time consuming. As for the flyweights, I am going to play with that idea of weight removal on another project soon. I am going to figure out a way to map the space cam changes when flyweights are lightened.
The 2.4 T pump rebuild I'm finishing up today has been upgraded with a #53 euro S space cam. I am starting the flow tests and calibrations today and will post the results.