The Mitsubishi Pajero Owners Club®

Mike terra · Posted: Mon Feb 13, 2017 8:05 Post subject: Zexel Injector pumps

Has anyone opened and serviced one of these ZEXEL injector pumps with electronic throttle, governor E.T.C.?

I had a failure of a pump due the the shutoff solenoid piston spring collapsing, the bits of the broken spring coil then got into the transfer pump and screwed that up the internal transfer pump.

Has anyone else on the forum had a 20 cent spring cost them close to $2000.00 to replace the pump. I have now seen 2 pumps with identical failure I guess not the only ones? Mad

Google · Sponsor

SteveW-DID · ***** Joined: 04 Jun 2006 Posts: 826 Location: Dorset

Don't know much about them personally. I have heard that once dissasembled repaired and reassembled they have to be calibrated on a test rig, Only a couple of companies in the UK have the required equiptment to test and calibrate them. I've often wondered if this really necessary.

Mike terra · Posted: Mon Feb 13, 2017 15:59 Post subject:

Steve,

Yes this was my thought as well. Over some years I have carefully disassembled cleaned and re-built a number of the 2.8 pumps after disappointing results from the pump repair shops. I found a supplier of seal kits in Dubai and I have had to replace couple of rotor heads and primary pump blades. they have gone back and run sweetly. Sometimes I think the 'MUST BE CALIBRATED" is actually overstated.

Question

VIKI · Posted: Mon Feb 20, 2017 20:34 Post subject:

As far as I know there is no way to properly setup zexcel injection pump electronic fuel dosage system without BOSCH testing bench, 3.2 injection pump is way more complex than standard old school EDC pump (fitted to 2.8 44M40) and even on EDC injection pump calibration was recommended for proper performance on zexcel injection pump(fitted to 4M41) there is no way of which I heard so you can properly calibrated fuel /air /engine temp mixture etc.

brianman · Posted: Thu Feb 23, 2017 14:25 Post subject:

Sausage machine · Newbie Joined: 21 Jan 2017 Posts: 8 Location: Wales

No idea but the conventional wisdom is no, but I may have an answer for you in a week or so when my injectors turn up. I bought a basket case 2005 Shogun cheap off ebay already partially dismantled and missing a couple of bits, got the error codes inc 46 and 48.

Having cleaned it externally then taken the GE actuator off and it's lid as well to inspect inside for swarf and or water or obvious mechanical failures, removed timing solenoid cover and plunger to check for damage, removed shut off valve and filter to clean and reassembled it all again as I didnt find anything obvious (except a small amount of swarf in the shut off valve filter and magnet and some very fine swarf in the fuel filter drainings) making sure the GE actuator body was positioned as near as damn it back where it came from, I tested it with fuel today on a bench and got 8 to 10 foot jets of fuel out of the fuel nozzles spinning it with my impact gun = probably not much more than idling speed. Not quite what I was expecting, will try that again with injectors on when they arrive and see what that looks like as I dont want it revving it's nuts off on 1st starts up.

I'm not spending £1500 rebuilding it even if i knew the truck needed nothing else doing (which I dont).

SteveW-DID · ***** Joined: 04 Jun 2006 Posts: 826 Location: Dorset

nvanders · Posted: Fri Feb 16, 2018 0:50 Post subject:

Goodevening,

Kicking this old thread up

Can buy a very cheap 3.2 shogun in good state, except de pump, when i read, there many issues with this type of zexel vrz.

Second hand also expensive, question is, what is usual broken or wornout on these pumps?

And are the repair kits / spare parts so hard to find? ( as stated before paying 1500 euro,s for maybe a small part broken sounds a bit ... ? )

I, repaired several pumps, and other very overpriced electronic equipment on cars, ( i,am electronic engineer so i have some skills )

Thanks

nvanders · Posted: Tue Feb 20, 2018 21:45 Post subject:

Someone ideas about this?, question still open

TxLDN · Newbie Joined: 19 Feb 2018 Posts: 9 Location: Bedfordshire

MARKS600K1 · Posted: Thu Feb 22, 2018 14:37 Post subject:

Hello

The consensus is the fuel filler pipes rust and fall to bits behind the rear wheel, water and dirt then gets in the system which eventually gets to the pump. I have a 2004 shogun with no issues the issues occur when the pump sees any water or dirt, moral of the story look after your filler pipes and check before you buy.

Regards Mark

nvanders · Posted: Sat Feb 24, 2018 21:13 Post subject:

What it causes is pretty clear, also the fuelfilter and the waterseperator does not do the job as it is engineered for,

i have seen a lot of dieselengines with very dirty filters and a lot of water and dirt in the trap under the filter, but without any pumpfailure.

So the zexel vrz is very sensetive for this, but still the question? which part in the pump is usually broken?

And including labour and parts does this have to cost about 1500?

assassin · Posted: Sun Mar 04, 2018 14:36 Post subject:

Mike terra · Posted: Sun Mar 11, 2018 6:18 Post subject:

From what I can see the problem with mine was the pump cam shaft bushes failed. I tried three methods of re bushings all failed eventually the pump housing had to be replaced US$ 2000 plus plus and plus if cars were not so heavily taxed the answer was to bin a perfectly good car! Laughing

nvanders · Posted: Mon Apr 30, 2018 16:53 Post subject:

So most failures are the bushings from the case ( pumphouse ) this piece of alu have to cost 1000 plus, pounds euros or dollars?

Cant this not be ordered at zexel?