FUEL PUMP RECONDITIONING

At Vag-Expert, we offer comprehensive fuel injection pump reconditioning. Our service includes replacing all seals with new ones, replacing damaged parts, thoroughly cleaning all components and the housing, adjusting, and reassembling the unit. Thanks to advanced technology and the experience of our specialists, reconditioned pumps work like new, delivering full performance and reliability.

If your fuel pump fails, you usually face two options: replacing it with a new one or having it reconditioned by a professional workshop. The cost of reconditioning typically ranges between 1,000 and 2,500 PLN. Buying a new high-pressure fuel pump can cost several thousand PLN — sometimes close to the value of the entire vehicle. Another option is purchasing a used pump, but this carries the risk of hidden faults and uncertain lifespan.

The most optimal solution is reconditioning, which involves replacing all seals, fixing damaged parts, cleaning, adjusting, and reassembling the pump. A professionally reconditioned pump operates just like a brand-new one. We use advanced, precise equipment designed specifically for repairing modern fuel injection systems. Our specialists’ precision and attention to detail ensure the highest quality service.

At Vag-Expert, we use state-of-the-art equipment and have a highly skilled team. We specialize in reconditioning various types of Common Rail pumps, including:

• Bosch Common Rail (types CP1, CP1H, CP3, CP4)
• Delphi Common Rail (types DFP.1, DFP.3, DFP.6)
• Siemens VDO Continental Common Rail
• Denso Common Rail (types HP2, HP3, HP4)

Thanks to their relatively simple design and minimal electronic control, injection pumps in older diesel engines could easily last for over 500,000 kilometers. However, stricter emissions standards and fuel efficiency demands led to traditional pumps being replaced by Common Rail systems.

Signs that your high-pressure fuel pump might be failing include:

• Engine won’t start
• Hard starting
• Lack of engine power and unstable RPM (engine surging)
• Black smoke from the exhaust
• Loud engine operation

The most frequent causes of fuel injection pump failure are:

• Mechanical wear of internal components, especially in high-mileage vehicles
• Use of contaminated diesel fuel (e.g., heating oil)
• Skipping regular engine oil changes (in inline pumps)
• Delayed fuel filter replacements
• Electrical valve failures
• Electronic control failures (especially in electronically controlled EDC pumps)

Fuel pump reconditioning at Vag-Expert follows these steps:

1. Disassembling the pump into individual components
2. Inspecting all parts, including under a digital microscope
3. Estimating costs and consulting with the customer
4. Cleaning all pump components using ultrasonic cleaners
5. Replacing damaged and worn-out parts
6. Replacing all internal seals according to manufacturer specifications
7. Reassembling the pump
8. Testing the pump on a test bench

Find out more about our fuel injection system services. www.commonrail-expert.pl