Diesel pump - double trouble

[Binsy]

I just had my leaky old diesel pump (JX 1.6TD) overhauled (all new seals etc) , new injectors, timing belt, water pump - don't want to think about how much it cost because I can't cry and type at the same time. Ran really nicely for 200km then spluttered to a 'tow me and my 2 small kids home' halt. The workshop has taken it apart and claimed that the problem lies in the pump they just overhauled, being contaminated from the fuel filter (that for some reason wasn't changed). Contamination that somehow has caught in the spinning bit that directs the fuel to each injector in turn and damaged it. Excuse my poor description but I haven't actually pulled this part of my van apart. They want me to believe in this evil form of contamination that somehow passed through a fuel filter with 10,000km through it, down the pipe and chewed a 'perfectly' rebuilt pump.

My question is, has anyone who has had one of these pumps apart, any idea of what might actually have gone wrong? Like, which bit they may have cocked up? Or can stuff like this really happen?

Any thoughts please....or at least write something funny to cheer me up.

[kevtherev]

They are dodging bullets.
Threaten real ones if it's not fixed, because even though trading standards officials do not turn green, they are scary.

[Timburrows]

The fuel filter stops the muck you put in the tank from getting to the pump,IF ANY MUCK HAS GOT INTO THE PUMP THEN THEY MUST HAVE DONE IT AS THEY TOOK IT APART?????? If your filters only done 10000 miles I doubt there's very much muck in it,my cars done 100000 on the same filter so I don't think the muck came from the filter

[Binsy]

Thanks guys....glad I was thinking right...... what can come through a fuel filter big enough to wreck a pump?? Would like to find out exactly what part ended up doing the damage. I will let them finish fixing it so we can fight over a repaired van rather than end up with them leaving me with it disembowelled. Kev; Trading standards here in Spain is a good idea - it is quite easy (remember this if you are travelling here); every business is required to keep a "libro de reclamaciones' which is basically a duplicate paper form that you can ask for to lodge a complaint be it a shop, restaurant ....and so it must be the same for a garage - will ask for it if they start getting really silly.

[Oldiebut goodie]

I am wondering if the filter has a by-pass if it gets blocked ( I know that that would be self defeating but it may be a possibility).

[Binsy]

Don't think so - there was a secondary connection at the top of the filter - I offered to get a replacement and the mechanic told me to get the type without this bit - I understood it to be (in heavily accented Spanish) something to do with pre-heating the fuel before it goes to the pump and deemed unnecessary in the Spanish climate. The new filter was just fuel in/fuel out

[Oldiebut goodie]

What filter was/is it - have you checked that it doesn't have a bypass? Some do.

[Binsy]

It had this type of filter - and I see now that yes it had a pre-heater: http://www.air-cooled-parts.com/cat/pro ... s_id=30491" onclick="window.open(this.href);return false;

[Binsy]

They got me to buy: http://www.air-cooled-parts.com/cat/pro ... s_id=30490" onclick="window.open(this.href);return false;

[Oldiebut goodie]

Can't see any mention of a bypass on either of them or several equivalents so looks like you can discount that as a possibility.

[Timburrows]

I didn't think a diesel filter had a bypass,in my experience in agriculture for 50 years when the filter is blocked the engine slowly dies the more power it needs the worse it is as it can't get enough fuel, does the pump look like it's been reconned ie very clean and like new? When a pump is reconned it done in a white room that is spotless so any muck in the pump must have entered after it was done May be in the garage ?

[Oldiebut goodie]

Some diesel filters do have a bypass - it seems to be a bit self defeating to my eyes but there must be applications where it is useful to have otherwise they wouldn't make them.
Usually when something like that is reconditioned it will come with protective caps on all orifices so it is nearly impossible to get detritus in when refitting. Someone has made a boo-boo somewhere down the line.

[Binsy]

Thanks for all your help and support everyone. I finally got the garage to sort it out. The boss was pretty dismayed at the problem himself. They had rebuilt the pump and he showed me the part that had failed - it is the 4 toothed plate that rotates and squirts the diesel to each injector in turn. It was deeply scored in the middle. He told me that the steel is so hard it is hard to mark it with a grinder and was at a loss for what could have done this. I agreed to pay for the new metal plate (around £100) and he took the hit on the complete strip down / rebuild. The new filter has been fitted (type without the heater bit). I am about to drain the tank and fit another new filter to avoid a repeat.

New injectors and new (or rebuilt) pump are great. So much smoother, much more power and jumps to life when starting even without the cold start being pulled out.