Einspritzpumpe/Relais? Kann jemand helfen, zu gefallen? Please!

Hallo!

Verzeihen Sie bitte dieser übersetzung, benutze ich Software, und ich habe einige sehr amüsante Störungen mit diesem System während vieler Erfahrungen gesehen. Ich bin englisch und ich bin nicht imstande, meinen Träger beginnen zu lassen. Ich bin in Portugal und habe 11 Tage, zum einer Reparatur durchzuführen, also kann ich nach Hause gehen!

Mein 1994 AAB 2.4D empfängt Kraftstoff nicht an der Pumpe. Ich habe Kraftstoff im Tank. Ich habe die Kraftstofflinie in Diesel eingesetzt, aber der Kraftstoff geht nicht zur Pumpe. Im Rückholschlauch gibt es Luft.
Ich habe einen Injektor, dort bin kein Kraftstoff entfernt.
Das Solenoid arbeitet, die Maschine Umdrehungen stark.
Kann jemand bitten mich zu gefallen, was ist dieser Bakelitkasten, der zur Einspritzpumpe angebracht wird?
http://i168.photobucket.com/albums/u162/sonysnaps/share/bosch.jpg
Ist das das Kraftstoffpumpeelement selbst? Es erhält nur 5 Volt auf dem unteren Anschluß mit der Zündung geöffnet. Sollte es 12v sein, und wenn ja, wie könnte es nur 5 sein? (Im Bild der Verzweigung, weiß ich, daß sie nicht richtig geschlossen wird).
http://i168.photobucket.com/albums/u162/sonysnaps/share/cnctr.jpg
http://i168.photobucket.com/albums/u162/sonysnaps/share/cnctrhsing.jpg
Ich kann nicht das Kraftstoffpumperelais finden, um zu überprüfen. Konnte jemand mir mit diesen Informationen helfen?
Was ist das Zündungsregelung-Relais, könnte, das das Angeklagte ist?
Im Handbuch gibt es Hinweis auf einer einspritzerpumpesicherung, Nr. 18, 20A. Ich habe die Leitung zum Solenoid und zum Kasten auf der Seite der Pumpe gezogen, aber keine von diesen beziehen diese Sicherung mit ein. Könnte jemand bitte erklären mir, wo dieser Stromkreis ist?
Traurig, soviel zu bitten, aber ich bin Meilen von überall hier!
Many Thanks in Advance!
MfG,

Cheers,
Paul
Original English version in case the translation is impossible!
Fuelpump / Relay? Can anyone help, please?
Please forgive this translation, I am using software, and I have seen some very amusing errors with this system during many experiences. I am English, and I am unable to make my vehicle start. I am in Portugal, and have 11 days to make a repair, so I can go home!
My 1994 AAB 2.4D does not receive fuel at the pump. I have fuel in the tank. I have inserted the fuel line into Diesel, but the fuel does not go to the pump. In the return tube, there is air.
I have removed an injector, there is no fuel.
The solenoid functions, the Engine turns strongly.
Can anyone tell me please, what is this bakelite box attached to the Injection Pump?
See Image 1 Above
Is that the Fuel Pump element itself? It gets only 5 Volts on the bottom terminal with the ignition open. Should it be 12v, and if yes, how could it be only 5? (In the image of the junction, I know it’s not correctly closed).
See image 2 and 3 above
I can not find the fuel pump relay to check. Could anyone help me with this information?
What is the Ignition Control Relay, could that be the culprit?
In the handbook there is reference to a fuel pump fuse, number 18, 20A. I’ve pulled the wire to the solenoid, and to the box on the side of the pump, but none of these involve that fuse. Could anyone tell me where that circuit is, please?
Sorry to ask so much, but I’m miles from anywhere here!

Cheers,
Paul

Hi,
translation software is a pain in the a**. So, let's try it in English.
I would suggest to check for 3 basic faults:
1. mechanical system (injection pump or its drive belt)
2. fuel system (clogged or taking air)
3. electrical system (fuel cut-off valve, immobilizer)
If you can live with it, have google (or so) translate that site: http://www.t4-wiki.de/wiki/Startprobleme.
All above-mentioned points are covered; for some you have to follow the appropriate links.
1. Check whether the drive belt is still attached. For that, you have to open the belt cover on the right hand side of the motor (standing in front of it); it's just two srews: http://www.t4-wiki.de/.../...r_Zahnriemen_Schutz_ESP_Schrauben_AAB.jpg
If the drive belt is ok, the pump may be broken. You can't really check that yourself.
2. Check that all fuel lines are correctly attached, concentrating on the fuel filter behind/below the right headlight: http://www.t4-wiki.de/.../...toffversorgung_Dieselfilter_Anschluss.jpg (ESP stands for injection pump)
Checking the fuel filter, you might consider draining some fuel from it to see whether it still takes fuel.
Make sure that the fuel tank is filled, to exclude the fuel sender as the 'bad part': http://www.t4-wiki.de/wiki/Tankgeber
Oops, should have read your article completely ;-)
Which fuel line did you insert into diesel?
3. Check all fuses and check the cables to the injection pump.
The part on the picture (hard to identify where it is mounted) most likely is the fuel cut-off valve which is connected to the immobilizer. Does look like an original part; see pictures on http://www.t4-wiki.de/wiki/Ventil_N109_%28Kraftstoffabschaltung%29
However, 5 V seems to be ok for me, because the valve must stay open even during start up, when the voltage typically drops to pretty low values.
There aren't any other electrical parts like pumps, relay, valves etc. which should/can be checked. The AAB fuel system is a completely mechanical one.
The Ignition Control Relay just controls the current through the glow plugs; no influence on the fuel system.

Hi UdoZ,
Thanks so much for your help, advice, and the information!
It is very kind of you to go to so much effort for this problem, I really do appreciate it.
The first thing I learnt was that I had put the exit pipe into fuel, rather than the entry line!! I had assumed the clear line ran away from the pump, when it is the other way round. So tomorrow I shall try the correct direction
This car has always been difficult to start, usually taking around 10 seconds, except when I re-start after a very brief stop, when it starts immediately. I suspected an air-leak, but with this problem, would I expect to at least see some effort from the pump to lift fuel? The car had been standing for three months; started, reluctantly as usual, then at the next attempt, a few days later, simply refused, and has done ever since.
I shall also remove the cover to check the belt - what is the large belt on the left of the engine, as you face the car?
Which are the cables to the injection Pump, please? I can only see the three to the Bakelite object, and one to what I assume is the Kraftstoffabschaltung.
Does this van have an immobiliser? I’ve not noticed it, but coming from a man who mixes up his fuel lines, this may not be a big surprise. Should I check this?
I have a few more images which I hope are an improvement on the original posting, and should make the problem clearer.
In the first one I show the location of the Part - Bosch, 1467 217 312 - from the front of the vehicle:
http://i168.photobucket.com/albums/u162/sonysnaps/locview.jpg
This next snap shows what I assume is the solenoid - (Kraftstoffabschaltung?)
http://i168.photobucket.com/albums/u162/sonysnaps/sol.jpg
It receives 12 volts, and clicks away happily, every time the ignition is opened.
Next is a picture of the whole area, with a few questions pasted thereon:
http://i168.photobucket.com/albums/u162/sonysnaps/sidebeltandqs.jpg
Lastly, here is an image of a clip - HWM 701 971 501C - that just ‘hangs around’, and I wondered if anyone new if that was the original intention?
http://i168.photobucket.com/albums/u162/sonysnaps/mysangle2.jpg
I shall post my progress tomorrow, and in the meantime wish yourself, and everyone else a very Good Evening.
Thanks again.
MfG from Portugal,

Paul

Hi,

Zitat:

Original geschrieben von isobars

Thanks so much for your help, advice, and the information!

You're welcome.

Zitat:

Original geschrieben von isobars

This car has always been difficult to start, usually taking around 10 seconds, except when I re-start after a very brief stop, when it starts immediately.

Have you ever tried - sorry, no idea what the english word is for Kaltstartbeschleuniger - to pull the small handle on the left hand side of the dashbord? It changes the injection timing, and facilitates the start-up when it's colder outside.

Another thing to check would be the preheat system (glow plugs, control relay, fuses etc.)

Zitat:

Original geschrieben von isobars

I suspected an air-leak, but with this problem, would I expect to at least see some effort from the pump to lift fuel?

Definitely - after a while, however.

Zitat:

Original geschrieben von isobars

The car had been standing for three months; started, reluctantly as usual, then at the next attempt, a few days later, simply refused, and has done ever since.
I shall also remove the cover to check the belt - what is the large belt on the left of the engine, as you face the car?

That is the one for the engine timing, it connects crank shaft and cam shaft. If this one is broken, your engine probalby had died completely. But you would notice it when trying to start the motor.

Zitat:

Original geschrieben von isobars

Which are the cables to the injection Pump, please? I can only see the three to the Bakelite object, and one to what I assume is the Kraftstoffabschaltung.

You are right. The one with only 1 cable is the cut-off. Assuming that your car has an automativ transmission, the other (with 3 cables) could be the kick-down switch for the transmission. But I'm just guessing, because I've never seen that thing before.

Zitat:

Original geschrieben von isobars

Does this van have an immobiliser? I’ve not noticed it, but coming from a man who mixes up his fuel lines, this may not be a big surprise. Should I check this?

The immobilizer was introduced around 1994/1995. And looking at the picture, in which you marked the cut-off, I'm sure that your car does not have one. So, you could check that valve by simply applying 12 Volts to it. Doing that, you should hear it 'click'.

Zitat:

Original geschrieben von isobars

I have a few more images which I hope are an improvement on the original posting, and should make the problem clearer.
In the first one I show the location of the Part - Bosch, 1467 217 312 - from the front of the vehicle:
http://i168.photobucket.com/albums/u162/sonysnaps/locview.jpg

Maybe the kick-down switch

Zitat:

Original geschrieben von isobars

This next snap shows what I assume is the solenoid - (Kraftstoffabschaltung?)

http://i168.photobucket.com/albums/u162/sonysnaps/sol.jpg

It receives 12 volts, and clicks away happily, every time the ignition is opened.

Working fine -> not a problem.

Zitat:

Original geschrieben von isobars

Next is a picture of the whole area, with a few questions pasted thereon:
http://i168.photobucket.com/albums/u162/sonysnaps/sidebeltandqs.jpg

Unsure:

Kick-down switch for the automatic transmission and - EDIT - the white hose (see-through) should be the feed line, the blue one the fuel return.

The yellow one could be an air hose for the increase of the engine idling speed during operation of the air condition. But I can't really see where it ends.

The second srew of the cover is on the opposite side, hidden by the smaller tube (top of the picture).

Zitat:

Original geschrieben von isobars

Lastly, here is an image of a clip - HWM 701 971 501C - that just ‘hangs around’, and I wondered if anyone new if that was the original intention?
http://i168.photobucket.com/albums/u162/sonysnaps/mysangle2.jpg

Sorry, no idea.

Zitat:

Original geschrieben von isobars

I shall post my progress tomorrow, and in the meantime wish yourself, and everyone else a very Good Evening.

Yes, please.

Moin,

Zitat:

Original geschrieben von UdoZ

The yellow one could be an air hose for the increase of the engine idling speed during operation of the air condition. But I can't really see where it ends

Very likely not. It should be the leak oil hose (injector nozzles).

Hi UdoZ,
I didn't mention, it has no Klima, but standhzg, it is a California WoMo - so maybe it deserves Klima!
Here is an image of where the yellow pipe goes.
http://i168.photobucket.com/albums/u162/sonysnaps/share/filters.jpg
Thanks again.
Paul
PS The papers show it is a '93 model.

Hi,

Zitat:

Original geschrieben von isobars

I didn't mention, it has no Klima, but standhzg, it is a California WoMo - so maybe it deserves Klima!
Here is an image of where the yellow pipe goes.
http://i168.photobucket.com/albums/u162/sonysnaps/share/filters.jpg

Yes, forget about the engine idling speed thing. The yellow pipe is the leak oil hose. It 'collects' the excessive fuel directly at the fuel injectors and spills it into the tank.

a: return line injection pump -> fuel filter

b: feed line fuel filter -> injection pump

c: feed line tank -> filter

d: leak oil line -> injectors -> tank

below: return line filter -> tank

By the way, I would like to use one or the other picture in T4-Wiki. Do you allow that?

Hi UdoZ,
Sorry for the delay, we have power problems in the storms.
Well, I made some progress today.
Firstly I removed the belt cover and observed the cog for the pump turning when I tried to start the engine.
http://i168.photobucket.com/albums/u162/sonysnaps/cogs.jpg
I blew air through the clear line: with the blue line removed there was strong pressure at the exit hole, this was with ignition on and off!
I blew air through the exit hole in the direction of the fuel line, this passed through easily.
I blew air through the blue line in the direction of the filters: this action allowed no air to pass. I could not generate enough pressure - with my mouth - for any air to leave the blue line.
I closed the blue line hole - that is I replaced the exit pipe - and blew air through the clear line: this resulted in air being forced out slowly through into the engine bay - I could hear it escaping, but could not determine from where.
I shall endeavour to find this tomorrow.
Should I prime the line with fuel before attempting to start the engine?
By all means, use any of my images as you wish, it's a pleasure!

Best wishes from A Stormy Portugal.
MfG,
Paul

Hi,

well, storms aren't a good environment for works on a car ;-)

Zitat:

Original geschrieben von isobars

I blew air through the blue line in the direction of the filters: this action allowed no air to pass. I could not generate enough pressure - with my mouth - for any air to leave the blue line.

That should be ok and as designed: the blue line ends in the fuel filter which possess a temperature controlled valve. If the diesel is cold, that valve closes the line from the filter toward the tank. The diesel now can circulate between injector pump and filter. Purpose: prewarming of the diesel.

http://www.t4-wiki.de/.../...gung_Dieselfilter_Knackfrosch_Prinzip.jpg

(orange line in the upper left hand corner of the picture

So, most likely, you were blowing air into the filter.

I guess that you isolated the problem quite well: the injector pump is not able to suck in the diesel.

Unless it is broken, I would now concentrate on the area tank-filter and check for any air leak or blockage.

Zitat:

Original geschrieben von isobars

Should I prime the line with fuel before attempting to start the engine?

I would. Frist, it makes it easier for the pump (needs diesel for lubrication), and, second, you will be able to see whether or not the pump sucks in diesel.

Zitat:

Original geschrieben von isobars

By all means, use any of my images as you wish, it's a pleasure!

Thanks a lot!

Hi UdoZ,
Thanks for the info. I am learning all the time!
A few questions, if I may.
Are these mechanical pumps prone to failure, until I bought the car it had covered 57K Kms in 14 years, now a year later it sits around 95K. Having said this, how critical is that lubrication to the longevity of the apparatus. Perhaps it has sat un-lubricated for many months over the years if a leak has allowed the fuel to fall away from the pump; is this a possible scenario? Could I assume that a repair to these pumps is a simple re-conditioning job, or is it more complex than that?
Lastly, is the air escaping as I blow down the clear tube going to give me the hint I expect in terms of the location of the leak, or should that be expected under the circumstances?
Once more, my most sincere thanks.
Salutations,
Paul

Hi Paul,
the AAB and its injector pump are very longlasting. It should, however, be filled with diesel all the time to prevent corrosion/rust and to keep the seals flexible. But I think, that the described scenario is rather unlikely.
Were you driving down to Portugal with that car?
The reconditioning would be quite a job and should be done by someone with good knowledge of it.
I would assume, that no air should escape, when you blow into the clear tube. But, I do not know it for sure.

Hi UdoZ,
Thanks for the info!
The car was driven to Portugal in September, and lay unused for three months, after this neglect it was started once for about a minute, and has refused all offers of liquid ever since.
I have primed the pump, I removed the exit bolt and poured in fuel until the exit hole overflowed. This happened quickly, is this normal with the ignition off? Would the fuel cut-off or the pump itself not have impeded it’s progress?
Anyway, unless you think it will be of no help, I shall leave the fuel to penetrate and lubricate a little overnight, and try again tomorrow.
Best wishes,

MfG,
Paul

Hi Paul,

Zitat:

Original geschrieben von isobars

The car was driven to Portugal in September, and lay unused for three months, after this neglect it was started once for about a minute, and has refused all offers of liquid ever since.

For about a minute? Then there was diesel in the pump and the pump was working.
Maybe it broke during that minute. But more likely, the diesel supply is interrupted by an air leak.
If you have the chance to fill up the tank, do it. By that, you would eliminate the tank sender as the source of your problem. Quite often the plastic attachment gets a crack, and - with the tank being half or so empty - air instead of diesel is sucked in. -> http://www.t4-wiki.de/wiki/Tankgeber
And then, I would give it a try: drain the filter a bit, fill it up with diesel, connect all hoses and have the starter run for a while watching for any diesel/air bubbles in the feed line (filter -> pump).
But don't let the starter run too long. It is not designed for that.

Zitat:

Original geschrieben von isobars

I have primed the pump, I removed the exit bolt and poured in fuel until the exit hole overflowed. This happened quickly, is this normal with the ignition off? Would the fuel cut-off or the pump itself not have impeded it’s progress?

Sorry, no idea.

Hi UdoZ,
I shall fill the tank tomorrow. It was very low when we stopped. Perhaps all the inactivity has led to this if there was a leak. Could the few seconds it ran be just on the fuel in the pump, perhaps?
Fingers crossed.
Thanks for the info!
Cheers.
Gruss.
Paul

Hi Paul,

Zitat:

Original geschrieben von isobars

Could the few seconds it ran be just on the fuel in the pump, perhaps?

Yes.

Zitat:

Original geschrieben von isobars

Fingers crossed.

Dito. Good luck.