Bosch Diesel Injection Pump Disassembly

Unread post by **CitroJim** » 04 Nov 2009, 22:27

Oh dear Kenny

That's one big danger of using ratchets in confined spaces

I've been there and done the same in the past...

yes, the old trick of double-nutting will extract the stud a treat. I've used that method in exactly the same place doing a Lucas to Bosch conversion as you need to move the studs to their alternative positions.

I recommend you replace the stud. One should be available at any breakers and again double-nut it out...

Hope all goes well from now on

MikeT wrote:I'm now convinced that all the orange contamination seen was gum/varnish and not rust (except the external distributor head).

Exactly my findings! I don't believe diesel goes like this as I've had jars of diesel sitting around for months on end with no apparent deterioration and I'm with you, in that what we're seeing is WVO residue. Taste it and see if you can taste any KFC or MaccyD in it!!!!

Again I agree that SVO is not going to cause any issues like this. It'll go sticky but soon clear once diesel runs through.

The gumming up is likely to cause initial problems but you'll have seen it cleans up quite readily so diesel running through should eventually
ungum it. What does worry me though is the effect it can have on the timing device. Did you notice just how fine the metering hole is in the piston? A bit of solid gum will soon block it for good and in one case I've had to poke it clear with a fine wire. Likewise, I've seen this varnish seize the metering valve in a Lucas so solidly that the engine would not start.

Unread post by **KennyW** » 05 Nov 2009, 15:29

Pump off but there was insufficient clearence to remove stud so i had to cut it

I have started removing the bolts and have only one left which is the long security bolt.

Also I have managed to recover most of the nuts which fell during the glow plug change overs

Going to leave it untiul tomorrow since it is sup[posed to be raining here

Kenny

Unread post by **CitroJim** » 05 Nov 2009, 22:45

Good stuff Kenny

I've posted a removal method for your bolt in your other thread...

MikeT · Unread post by **MikeT** » 06 Nov 2009, 17:53

Good going. Keep us updated Kenny, I've yet to attack my armoured pump and probably won't do so until next week.

Have you considered replacing the seals while it's off the car? The seal life is given to be 10-15 years so worth doing at this point in time IMO. I think the new seals are also improved to take account of the changes in fuel properties, including biodiesel.

It'll also give you an opportunity to modify it, should you be inclined 8)

Unread post by **KennyW** » 08 Nov 2009, 18:44

Further to my last reply and my post on the citroen site:

Ihave removed the 2nd bolt with little fuss but encountered another minor irritation.

On the armour above the stop solenoid is held on by a hex screw and a hollow split pin.

Screw is off but the pin is being a little awkward. I have the pin rotating in the hole but can't remove it totally.

Will keep you posted about my method of removal incase your pump has the same Mike.

Can you confirm your pump number as it may not have this pin.

Kenny

MikeT · Unread post by **MikeT** » 08 Nov 2009, 22:25

I can't read the one on my Xantia yet but the spare (from a MK1) is

0 460 494 427 It's got sheared headed security bolts from what I can see - can you photo this pin you found? I'm reading your posts with great interest.

Unread post by **KennyW** » 09 Nov 2009, 20:03

Hi Mike,

Oops my pin is fitted

but if you look on the peugeot section you will see Lawrence describes it as a roll pin and a great method of removal.

If you look at your pump it will be obvious, the body armour over the stop solenoid will be secured with a hex screw and the pin ( after removal of the other armour). If you look at the pump from the unions my screw was on the left and the pin was on the right.

Jim, did say my pump was a later model and the design has slightly changed.

I'll try and photo the old pin which has been reradjusted

Kenny.

MikeT · Unread post by **MikeT** » 09 Nov 2009, 22:06

Hi Kenny, good to know you got it de-armoured and overcome this pin problem to eventually fix the fault, well done.

Will you be putting it straight back on or fitting new seals first?

Unread post by **CitroJim** » 09 Nov 2009, 22:19

That's brilliant Kenny and delighted Lawrence came up with the answer

Some pictures would be great

Unread post by **KennyW** » 09 Nov 2009, 22:46

Hi Mike and Jim,

Unfortunately the time it took for me to remove the armour has caused me to put it all back together as I need the car for Wednesday.

Hopefully everything is fine as I fitted everything back on in about 2 hours ( week to remove

). Only need to finish fitting aux belt, wheels & thats about it.

No pics as camera batteries flat as the preverbiable.

Kenny

Unread post by **KennyW** » 10 Nov 2009, 20:30

Hi Mike and Jim,

Rebulit everything and its not starting so with the assistance of a friend who is a timed served mechanic we have checked the following:

1.Fuel supply into pump - Yes
2.Fuel supply into injectors - No
3.Fuel supply leaving pump for injectors - No
4.Stop solenoid (removed) supplied with 12v worked

5.Electrical connection to immobiliser, stop solenoid 12V at connector at pump

Our conclusion is there is a problem with the pump.

I am considering doing the overhaul, your thoughts on this would be appreciated.

Kenny

Unread post by **CitroJim** » 10 Nov 2009, 22:30

Shame this has not had a successful conclusion yet Kenny

Still, at least you're practiced at pump removal now; a bit like me with V6 engines

Yes, time to delve into the pump. Be interesting to see what you find.

I've a large document on how the pumps work with lots of line diagrams. It's far too big to post on here but if you'd like a copy in PDF format, I'll be very happy to email it to you. It may prove very helpful in conjunction with Mike's excellent work here.

Unread post by **KennyW** » 10 Nov 2009, 22:34

Thanks for that Jim,

I will PM you my e-mail address for home and work, run out of ink at home might as well use the works printer

Lawrence believes this is similair to problem he had with his pump.

Kenny

Unread post by **KennyW** » 10 Nov 2009, 22:43

Jim,

I tested the old stop solenoid out of the pump by attaching a wire from the +ve terminal on my spare battery to the stop solenoid which was sitting ontop of the -ve terminal of the battery, hence the reason I know the solenoid is working.

Sorry for the confusion.

I will have to remove the pump again de armour same and re test solenoid in the pump if it is working will fit pump and see if engine will start minus the armour.

Kenny

colinxm · Unread post by **colinxm** » 10 Nov 2009, 23:02

Hi Mike, great posting - thanks ! I've just rebuilt my pump and am having trouble getting it to run correctly now, wish I'd have found your thread before I started

Cheers, Colin.P