What not to do to a diesel

[colinxm]

Hi Mike, I think you've missunderstood my question but after reading what you wrote last I now understand what you meant about the accelerator arm positioning being important (if you understand what I mean ). I don't wish to change anything really, 'as things were' will do just fine for me, wish I'd have marked things up better - doh !

Jim, many thanks for the pdf, very much appreciated

Right, the pump is on the dining table and I'm armed with a big set of tools and several cold beers, watch this space !

Cheers, Colin.P

[Geoff Lebowski]

Cold beers! Uh oh!

[CitroJim]

and several cold beers, watch this space !

Mind you don't get any in the pump Colin

All the best for a fully successful rebuild this time

[MikeT]

Hi Mike, I think you've missunderstood my question but after reading what you wrote last I now understand what you meant about the accelerator arm positioning being important

Sorry Would you mind rephrasing the question? But good to know I'm making some sense.

[colinxm]

Thanks Gents, the deed is done ! I only drank one beer, didn't spill any and don't have any bits left over from the rebuild

On a more negative note. I didn't find anything obviously amiss either so I'll probably be in the same boat when I refit the pump tomorrow...

Wish me luck, Colin.P

[colinxm]

It works ! ticks over nicely and revs up just as it should. a little tinkering with the fuelling screw and I think all should be well, this was how it looked last night:


Good job Mrs.P was out still don't know what was wrong with it before though...

Now for the bad news... the engine isn't quite right and there's a metalic hammering sound from the valves area, further inspection revealed:



Looks as if I didn't get away with introducing the valves and pistons after all, thankfully it's only one that's broken and it's a relatively easy job to replace.

Thanks once again to MikeT, Jim and Geoff for all your help and support, you're all wonderful human beings

Best wishes, Colin.P

[MikeT]

Thanks for the feedback Colin and am really pleased you cured the pump fault - any idea what it was?

But sad news about the engine - to a degree as it could have been worse. Seems like you're on the way to getting the car back on the road at minimal cost other than time.

[colinxm]

Hi Mike, Sadly I haven't a clue what was wrong, I rebuilt it exactly as I had done before as this corresponded with the photo's I took as I dismantled it the first time around. I did introduce each component and the housing to a good blast of compressed air so perhaps this dislodged something that I'd missed before other than that I haven't a clue

I've found a spare rocker finger from out of the shed so I'll atack the engine again tomorrow after work then I can give it a run and see how the pump performs.

Cheers Colin.P

[Geoff Lebowski]

Excellent news! All the more frustrating to find you put the pump back together perfectly to begin with!

[CitroJim]

Colin, that is brilliant news Absolutely delighted

Shame about the rocker but at least it's not the camshaft or a bearing cap. Good old 2.1TDs, they're tough old birds really.

I'm smiling here...

[colinxm]

Geoff, thanks for that, can't promise that I actually did put it back the same as last time but I'm pretty sure I did - just one of those things, I've sure learned alot about how these pumps actually work though so it was worth it for that

Jim,thanks, I'm smiling too you're right of course, there's alot to be said for these older engine designs - almost bomb proof (good job too !)

Best wishes Colin.P

[Geoff Lebowski]

I learnt a lot too. In fact I owe a a lot to Jim as it was his website that inspired me to pull a pump apart and a BE3 gearbox! Jim has also been on the end of the email many times offering help and support and indeed parts!

It's amazing what you can learn from doing these things. When I 1st saw the Bosch strip/rebuild on a VW forum I thought 'no way, that's too much for me, I'll mess that right up' but with the pdf file Jim sent you and actually taking a pump apart, it's amazing what you can learn. Not that I could ever come close to designing the thing but it's a very clever bit of engineering.

When I think of internal combustion, if some one had said to me "you know, if you can make petrol and air explode, it'll expand the air/gasses and push a piston and make things move" and "if you make it do it 4000 times a minute (60+ times per second!) I'd of said forget it, never work!

Then you think of all the systems and sub-systems that go along with cars these days - it's really an art of engineering. On that note, my Dad has just bought a 2nd hand C5 Estate (latest marque) with the hydropneumatic suspension. I'll have to twist his arm for a drive! fingers crossed!

[colinxm]

Today I replaced the broken rocker finger, changed the engine oil and took the xm out for a test drive. It was a bit too smoky so a little adjustment of the fueling screw was made and the car now goes a treat and is totally leak free, I was so pleased I even gave it a wash

That sorted I now need to find out why the passenger side (LH drive car) floor carpet in my wife's Pug 307 is wet - should be a doddle after the Bosch

Colin.P

[MikeT]

Hello again Gents, I managed to get to poke around with the pump a bit today I removed the LDA and pin/diaphragm, the fuelling pin was nowhere to be seen but duly popped into sight when I operated the accelerator, I tried this several times proving that this is ok. I then pulled off the whole top,

I know I'm slow. But while grinding away at my armour today, my mind wandered over to the procedure for top removal and this paericular post came to mind.... How on earth did you manage to get to the cold start spring with the pump installed Colin

[CitroJim]

How on earth did you manage to get to the cold start spring with the pump installed Colin

With great difficulty I'd imagine I have enough trouble with that spring when the pump is sitting on the bench