Reviving this thread because of more and more Injection pump threads/questions.
Our 4D56 IP bodies share similarities with the Bosch VW IP's.
Many VW's imported from Germany end up having to get an IP overhaul after being driven here as do JDM diesels (landcruisers,etc..)
It's the sulfur diesel quality and stop & go traffic that attributes to most of the IP issues here in Canada.
I've had four IP's rebuilt recently and some VW's in the past. Two with a general rebuild/seals/clean and two with a complete overhaul (sleeve/solenoid/boost pin/cam plate/plunger, etc.. replaced) and recalibrated to manufacturer specifications.
If you notice your IP leaking, it may just need new seals and an internal cleaning.
If you notice you have lack of power and/or excessive smoke and have tried everything under the sun to fix the issues, then you may need an overhaul.
I find explaining this to some people difficult because there is a significant difference between a rebuild and a rebuild.
What ? a rebuild and a rebuild ?
That's right.
You can have you IP rebuilt differently at one service center compared to another.
Normal rebuild - Disassemble, clean, reassemble with new seals, set vehicle timing.
Major rebuild - Disassemble, clean, replace worn internal/external parts, calibrate internal pump timing, reassemble with new seals, set vehicle timing.
There is a big difference between the two.
You will notice/feel it in too ways :
1. your wallet. Normal rebuild 350-800(avg 500) compared to Major rebuild 800-1500(avg 1000)
2. peformance. normal rebuild - less smoke/ no leaking compared to major rebuild - less smoke/better mpg/increase in HP/ no leaking
About as clear as I can slice it.
Most people have work performed on their vehicles based on their wallet and not what the vehicle actually needs.
Given that, a normal rebuild in most cases is fine.
I opt for long term preventative maintenance and refer people to get a major rebuild since it's being pulled out and disassembled anyways.
As for the shop doing the overhaul.
The Delica engine (4D56T) injection pump has the same parts as common VW Bosch injection pumps.
That means that you can take it to any injection / diesel specialist to get it done.
The timing/dial set tool used for this type of injection pump (Mitsu/VW/Bosch) can be bought as well if you plan on setting the timing yourself (ie. set back or advance the timing depending on how you want to tweak it). This is only recommended for 'real' mechanics and not 'DIY' mechanics. 'recommended' being the key word.
Jesse