Factsheet updated 3 October 2008

Diesel fuel injector pump

This factsheet describes how a fuel injector pump works, looks at the different types of fuel pump used on a Bongo and some troubleshooting issues, including an illustrated guide to how to change the injector pump seals. Technical rating (main section): fairly easy Technical rating (injector pump seals section): quite tricky What is a fuel injection pump? Compared to carburettors (their predecessors in the fuel pump game, used on most pre-1990 model vehicles), fuel injectors themselves are incredibly simple. They are basically electro-mechanically operated needle valves. When a current is passed through the injector electromagnetic coil, the valve opens and the fuel pressure forces petrol through the spray tip and out of the diffuser nozzle, atomising it as it does so. When current is removed, the combination of a spring and fuel back-pressure causes the needle valve to close. This on-off cycle time is known as the pulse width; varying the pulse width determines how much fuel can flow through the injectors. When you ask for more throttle via the accelerator pedal this lets more air into the intake system. The position of the throttle is measured with a potentiometer. The engine control unit (ECU) gets a reading from this potentiometer. In response the ECU increases the injector pulse width to allow more fuel to be sprayed by the injectors. Downwind of the throttle body is a mass airflow sensor; this is normally a heated wire. The more air that flows past it, the quicker it dissipates heat and the more current it needs to remain warm. The ECU thus continually measures this current to determine if the fuel-air mix is correct, and can adjust the fuel flow through the injectors accordingly.

Fuel sensors In order to provide the correct amount of fuel for every operating condition, the engine control unit has to monitor a huge number of input sensors. Here are just a few: Mass airflow sensor tells the ECU the mass of air entering the engine Oxygen sensor(s) monitors the amount of oxygen in the exhaust so the ECU can determine how rich or lean the fuel mixture is and make adjustments accordingly. Throttle position sensor monitors the throttle valve position (which determines how much air goes into the engine) so the ECU can respond quickly to changes, increasing or decreasing the fuel rate as necessary. Coolant temperature sensor allows the ECU to determine when the engine has reached its proper operating temperature. Voltage sensor monitors the system voltage in the car so the ECU can raise the idle speed if voltage is dropping (which would indicate a high electrical load. Manifold absolute pressure sensor monitors the pressure of the air in the intake manifold. The amount of air being drawn into the engine is a good indication of how much power it is producing; the more air that goes into the engine, the lower the manifold pressure, so this reading is used to gauge how much power is being produced. Engine speed sensor monitors engine speed, which is one of the factors used to calculate the pulse width.

There are two main types of control for multi-port systems: the fuel injectors can all open at the same time, or each one can open just before the intake valve for its cylinder opens (this is called sequential multi-port fuel injection). The advantage of sequential fuel injection is that if the driver makes a sudden change, the system can respond more quickly because from the time the change is made, it only has to wait only until the next intake valve opens, instead of for the next complete revolution of the engine. The Bongo fuel injection system As youd expect there are a large number of components that make up the Bongo fuel injection system. And again as youd expect, a number of these are prone to occasional failure or need periodic replacement. This section, much of it gleaned from the Bongo Fury technical forum, highlights several common problems and incorporates members suggestions for fixes and obtaining spares. Tip: apparently the Bongo uses a Ford Ranger engine, so spares that fit the Ranger will be suitable for the Bongo also. Bongos from 1995 to January 1999 use a mechanical fuel pump, but models from Feb 99 use an electrical or fly-by-wire system. For the technically-minded, schematic diagrams are shown at the end of the factsheet. These have been reproduced from the Mazda electronic parts catalogue, a copy of which is available in the members area of the club website.

Club members have recommended Lawson Diesel, an Edinburgh-based garage specialising in fuel injection systems. For more information, see www.lawsondiesel.co.uk or phone 0131-555-1950. O ring replacement The O ring between the front cover and back plate of the injector pump can fail, causing a leak. These are made by Bosch and have part number 2 460 223 001 000. They are stocked in the club shop. Throttle position sensor The Mazda throttle position sensor is manufactured by Zexel (Bosch); part number is 146684-6621. The equivalent Bosch part number is 9 461 619 201. Replacing the injector pump seals This section shows how to replace the fuel pump seals. Time: about two hours Tools needed: 10mm combination spanner 10mm socket wrench small hands (!)

1. Heres the leakage.

2. Run your hand under here to find the source of the leak.

3. Check you can get your hand into this space.

4. Remove the power steering reservoir and air inlet pipe.

5. The domed cover houses the adjusting spring and shim for the advance piston. Directly opposite, at the engine block side, is a banking plate that the advance piston stops against: this is where most leaks occur.

6. Carefully remove the dome cover; there is no spring pressure on the bolts. Take care that the adjuster plunger and sleeve do not fall out: there is a double spring assembly and shim set under these which are easily lost if dropped. Some diesel will be lost when you

remove the cap. Then remove the plate diagonally opposite. Note: you cannot see the blanking plate, you have to feel it from below the pump.

7. Adjusting shims

8. The removed plate will look something like the left-hand picture, scored after years of being bashed by the plunger. Rub with T-Cut and emery cloth until it looks closer to the plate in the right-hand picture.

9. Seals. 10. Before removing the seal from the banking plate, fit a new seal into the recess in the pump body (add some fresh diesel). Refit the domed cover and adjuster (tighten about six threads). There will be space behind the plunger to use a fingernail to prise out the original seal from the hidden blanking plate side. Push the new seal into its recess behind the blanking plate and refit the cover. 11. Tighten bolts on the domed cover evenly against the spring. Refit the air inlet pipe and power steering reservoir. Crank the engine on full throttle to bleed the pump, then start.

Bongo fuel injector pump schematic diagram (pre-1999 models) For detailed description of the part numbers, see page 1362C of the online parts catalogue at http://www.lushprojects.com/bongopartsmk2/

Bongo fuel injector pump schematic diagram (post-1999 models) For detailed description of the part numbers, see page 1362A of the online parts catalogue at http://www.lushprojects.com/bongopartsmk2/

Factsheet complied by Matthew at the Utility Bongo Research Kitchen, using material from a variety of sources including the technical area of the Bongo Forum (special thanks to dandywarhol for the section on replacing fuel pump seals), www.carbibles.com and www.howstuffworks.com . Bongo Fury welcomes members contributions to our factsheet series. To report errors or omissions, or suggest updates to this factsheet or the series contact ian@bongofury.co.uk . For more technical advice and information visit the member forums at www.bongofury.co.uk Bongo Fury 2008. For the sole use of members of Bongo Fury, the Mazda Campervan Owners Club. Not to be reproduced or passed on, in whole or in part, without permission. The Bongo Fury logo is protected by copyright. Important legal disclaimer: the views expressed in this factsheet are those of the contributor(s) and do not constitute professional advice from Bongo Fury, the Mazda Campervan Owners Club. Bongo Fury cannot be held responsible for any vehicle damage, injury or financial cost, whether to yourself or others, incurred as a result of following the advice given in this factsheet. If in doubt contact a qualified professional or your local service centre.