Diesel Fuel Pump Testing Calibration Repair Service
Page updated 10-07-12
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We are equipped with the latest software and calibration equipment to test, calibrate and repair all Bosch, Delphi, Denso, Lucas CAV, Rota-diesel-marine, Cummins, Simms, Caterpiller and GM EDC diesel injection fuel pumps. We are also equipped & stock spares off the shelf, to calibrate & repair many other types of inline/rotary pumps.
We specialise in: VE-EDC (resistive actuator) VE-HDK (inductive actuator) HDK/SP Bosch VP44 & VR30 Bosch CP1 & CP3 Bosch in line VE-H-M-P-R inc P1700 P8500 MW PFRK-Q Zexal Covec T+ F1 & F2 Delphi DPCN Delphi EPIC Denso VE-ECD CAV DP-A-S-C Sigma CMS-RM-RMS Lucas DP210+Epic
Inspection/testing fee: Bosch-Delphi-Lucas £69.50
Inspection/testing fee: Siemens-Denso-Sigma £79.50
Bosch pump repairs range from: £60 - £250 Average repair cost is £165ish (on top of test fee).
Calibration only using ISO 4113 fluid: £40 (on top of test fee).
PDC-PSG5-PSG16 EEPROM re-programming & KAL-on live flashing: (Price on application).
Exchange pumps (Price on application).
Common Rail High Pressure Pumps. We have a test bench plate adapter to mount Bosch single port pumps. We can drive and phase & test for pressure and volume. Our workshop stocks most common spares, any unusual spare parts will need to be ordered over night from Leicestershire.
Testing fee is £59.50 (to include return packaging & postage/insurance).
Turn-a-round times for testing & repairs is 24hrs.
Please include the ribbon- IBM type cable from older VE type pump only, main lead from pump control module to host loom. With the pump when sending for testing. As about 35% of these leads prove to fail when tested, but the host pumps are ok. But these can only be tested with pump or by substitution with another cable. CAN bus twisted pair type wires are very reliable and have proven not to malfunction.
ENCLOSED with the pump should be:
Details of vehicle make, year & model
A list of vehicle fault symptoms and any diagnostic work carried out.
Return address, phone number and current email address (as we are moving towards paperless system of reporting & billing).
When posting pumps for testing please fill in & print off this form and include it with your pump.
Without exception no testing will be enacted for non-account customers without pre-payment.
Debit card payments are free, but we charge 5% for credit card payments.
We also accept PayPal payments to firstname.lastname@example.org
Pumps travel well inside a cardboard box, padded with newspaper (please drain off fuel & plug orifices if possible, wrap pump in sealed black bin-bag before packing, as not to offend my postman with the smell of diesel). The cheapest option is ParcelForce48 available at any Post Office, which can be tracked via Royal Mail website.
Post to the following postal address:
Auto-Tec Diagnostics, Unit 7 Austin Fields Industrial Estate, King's Lynn, Norfolk, PE30 1PH.
Please email for EU and overseas postage costs, method of payment, we except the €uro (no Western Union please) plus details of turn-a-round times (EU postage costs are not prohibitive).
Note: EDC diesel injection pumps cost a fortune to replace new! £900-£1500. Exchange ones are about £515. Testing at £69.50 is good value against replacement, if only to prove its working & exclude it from the diagnostic process, proving function of the pump by the substitution of an expensive new one, is just a waste of money. Bench testing is the only definitive method, because it excludes the vehicle's host wiring & fuel supply.
It is inevitable some pumps sent for testing and inspection are unrepairable! Some pumps are so borderline for repair, if we were to repair them they may not last the length of the warranty. We on occasions take the commercial decision not to repair. In the long term this is better for the customer. It negates the painful task of having to remove the injection pump for a second time to return it for a warranty claim.
Info about re-programming: PSG5 pumps. If you are considering fitting a second-hand one! Most VW & Rover pumps will need re-programming, its a bit hit & miss with GM Vauxhall & Ford, some will need programming, some will not! Its a bit of a myth that they all need doing (ex main-dealers). It's all to due with matching protocol & setting the parameters, not security numbers. But it has to be said, that several of our trade customers have retro-fitted second hand pumps, expecting problems and they have subsequently started & run ok. Very few EDC pumps will need a Bosch KTS type laptop connected to the 16pin diagnostic plug on re-fitting, to set min/max fuel delivery, IE volume, idle speed! Governed RPM min-max. All the settings are the same ex the factory, these settings only get altered, if the pump has been fitted to different vehicle, or the settings have been changed in an attempt to overcome a problem. Bosch pumps are the most user friendly in this department.
GM Vauxhall EDC pumps are notoriously difficult to diagnose in situ, many main dealers fail to conclusively make a diagnosis, we have heard from our trade customers about horror stories about new pumps being fitted when not needed.
Early EDC pumps are known to fail from "cavitation" due to an ingress of excess water. Water separates out from the fuel over time in diesel filters, and if the filter housing is not drained down at the correct service intervals. The water will damage the pump beyond repair. Most car manufacturers are now fitting new type water level sensors to filter housings on new models. Supermarket fuel is jokingly called emulsion in the trade, due to its high water content. Its cheap for a reason! Some early VP44 pumps are known to fail due machining errors in the axle rota head, a few of these wreck the alloy pump body, rendering the pump unserviceable.
PSG16 (Twin plug pumps) This Bosch 44 terminal version contains a read/write 16bit flash memory in the PSG16 module. Where the engine management maps are stored. Other issues are that the headers are pump assigned which you cannot change or interchange between used pumps, spooling solenoids are the same as the PSG5 units and can be interchanged.
PSG16 new pump warranty. Most people in the trade have stopped selling new Bosch PSG16 (twin plug) pumps. This is due to a major change in how Bosch deal with warranty claims. Even thou these pumps cost between £1380.00 and £1800.00 new. Should you wish to return one under warranty to us, it may take Bosch 8-12 weeks to process your claim. Which means after removal and returning the pump, you may not be able to use your vehicle for up to three months. Till Bosch settle the warranty claim. We will not credit you a new pump untill Bosch give a decision!
PSG5 new EDC warranty. This is due to a major change in how Bosch deal with warranty claims. Should you wish to return one under warranty to us, it may take Bosch 5-6 weeks to process your claim. Which means after removal and returning the pump, you may not be able to use your vehicle for up to six weeks. Till Bosch settle the warranty claim. We will not credit you a new EDC untill Bosch give a decision!
Parts for later (>04) Denso pumps are very-very expensive and can take up to ten days to arrive.
Typical Bosch parts prices for non genuine pattern replacement parts from stock.
Head & Rotor for VE Pump £225.80 - £400.30
Plunger & Barrel for A, AD, P, B, £35
Plunger & Barrel for MW, P1700, EP9, £26.80 - £31.40
Delivery valve £25.10
Pencil Nozzle 27333 £27.83 - £38.12
PSG5 modules £141.00
PSG16 hybrid modules POA
(part prices above only, plus fitting charge for labour)
We also stock new Bosch Lucas Delphi OE parts of the shelf, email for more info/prices.
We have tons of secondhand parts from old or new pumps, so if you need a small part or simply ruined a thread on something email for availability & price.
For trade enquiries, if required, we will supply pump parts only. We are very competitive on parts prices with larger volume orders.
info on red diesel-vegetable oils
info on EDC pump numbers-application
secondhand EDC diesel pumps - rail injectors - HP pumps & parts for sale
Test results: All test results will be given out verbally over the phone at the point we have tested your pump, this is our standard method of quoting out repairs. We will ring on the day of the test. Please do not request a test report long after the test has been enacted. The imformation will simply not be availiable. This is aimed at keeping our test fees as low as possible. It is also how the trade likes it. No delays in quoting out repairs and returning the pump in question. We reserve the right to charge for a written test report after we have provided the information verbally.
All exchange pumps and injectors c/w a 12 month unlimited mileage warranty.
All fully serviced pumps and injectors c/w a 12 month unlimited mileage warranty. All part serviced pumps c/w a 90 day unlimited mileage warranty.
Repaired pumps using secondhand parts c/w a limited warranty or no warranty. The details of this will be explained at the time of purchase.
Should a suspected warranty issue arise please return the suspected item to us
for examination along with details of the problem and invoice number. We will
resolve all warranty issues as quickly as possible.
Warranty exclusions – The warranty of our pumps and injectors will be void if any of the following are found upon examination: Fuel damage. Water contamination. Acid/chemical contamination. Dirt or other foreign material. Unauthorized adjustments. Physical damage. Incorrect fitting or poor electronic commissioning.
Fuel damage. Water, corrosion, contamination, and rust are some of the things we have seen inside failed VP44 injection pumps - Bosch refers to these conditions as “Contaminated Fuel” and invalidate warranty as a result. Savings achieved by using alternative fuel is likely to cost you a lot more long term, especially when your warranty claim is rejected. Modern injection pumps with high pressure and the close tolerances cannot survive the abuse caused by cheap alternatives. It is crucial that vehicle owners are aware of the potential hazards of alternative fuel. We strongly advise that when a pump is repaired or replaced, the customer also inspects the fuel, fuel tank and fuel filters, because bad fuel left in the vehicle can cause quick death of the repaired or new pump. Only the customer has control over the fuel used and must take responsibility for that factor.
PSG16 new pump warranty. Most people in the trade have stopped selling new Bosch PSG16 (twin plug) pumps. This is due to a major change in how Bosch deal with warranty claims. Even thou these pumps cost between £1380.00 and £1800.00 new. Should you wish to return one under warranty to us, it may take Bosch 8-12 weeks to process your claim. Which means after removal and returning the pump, you may not be able to use your vehicle for up to three months. Till Bosch settle the warranty claim. We will not credit you a new pump until Bosch give a decision!
PSG5 new EDC warranty. This is due to a major change in how Bosch deal with warranty claims. Should you wish to return one under warranty to us, it may take Bosch 4-5 weeks to process your claim. Which means after removal and returning the pump, you may not be able to use your vehicle for up to six weeks. Till Bosch settle the warranty claim. We will not credit you a new EDC until Bosch give a decision!