Bosch Diesel Injection Pump Disassembly

MikeT · Unread post by **MikeT** » 10 Nov 2009, 23:48

Hi Kenny, sorry to hear all your hard work hasn't brought the result you were aiming for, that is disheartening but good to know you're still in the fight!

Although testing the soleniod has shown it's working ok, it doesn't rule out it failing when fitted. A quick test if you can access it in-situ; remove and refit the stop solenoid sans plunger and spring (meaning, should it start, you will only be able to stop the engine by the stop lever on the pump or blocking the air intake). Failing that, I don't know what to suggest other than a pump rebuild at this point in time.

Hi Colin, Thanks, I hope the post has some info you can still make use of. I've tagged another suggestion onto Jim's advice in your thread rather than deal with it here, if that's ok?

Unread post by **KennyW** » 11 Nov 2009, 23:41

Hi Mike,

I have another thread running on the peugeot part of the forum and Lawrence 1973 has had avery similair problem which was solved by re wiring the solenoid.

Will start job Sat and will tak pics etc and if you wish I shall try to add them to this blog if you are happy with that.

Kenny

Unread post by **KennyW** » 15 Nov 2009, 20:51

Hi Mike and Jim, here are the images I took on Sunday 15th

Unread post by **CitroJim** » 15 Nov 2009, 21:10

Kenny. that's brilliant, all now becomes 100% clear and it will be invaluable for future dearmament operations on the later pump

Thanks very much for posting up these pictures $\:D/$

Mike, I've sent a Lucas pump back with Toby for you. It's a non-turbo one from a 205. It is a mess inside. It has a missing stop solenoid unfortunately.

Thanks ever so for the cabin temperature sensor!

MikeT · Unread post by **MikeT** » 15 Nov 2009, 21:22

Thanks Kenny, I replied on the other thread

forum ping-pong anyone?

You're welcome Jim - just sorry the front cover got unglued though for his (my nephew) first attempt, he didn't make too much of a mess of it. Thanks for the pump though not sure when it'll get attention - having too much fun with these bosch's at the moment.

MikeT · Unread post by **MikeT** » 15 Nov 2009, 21:36

Now I'm about to strip a pump off a Xantia 1.9TD MK1 that had been scrapped due to a failed gearbox.

I see that although these pumps looks the same at first glance, they come in many different configurations, which is not surprising as Bosch intended them to have plenty of add-ons. What I didn't expect was they even come with different brackets and in the case of this Xantia pump, some armour bolted down with security head-sheared bolts.

Here we can clearly see four of them and the fifth is partially obscured by the lower left delivery valve.

This is how I tackled the two exposed bolt heads after removing the valve

Once the slot was cut, an impact driver and one smart clout got it turning with a screwdriver. Two down, three to go.

Two of the shrouded bolts were given the same treatment but it meant cutting into the shrouding slightly. Then my dremel needed a recharge.

Unread post by **KennyW** » 15 Nov 2009, 21:58

Hi Mike and Jim,

I think to keep things easy I will reply on this blog.

Mike,

When you removed the Union what came out and can you photo that as well.

I was think about removing one or two of them to help access.

Kenny

MikeT · Unread post by **MikeT** » 16 Nov 2009, 21:30

Sorry for the delay in posting Kenny.

Be careful if you haven't removed a delivery valve before
It's spring loaded with several small parts that might jump out of position
Leaving you wondering how they go back together.

In order of fitment from valve to head, you will find the following

The delivery valve, two or more shims that stick together, a spring, a plunger, a plunger seat and copper washer.

Refitting is even more fun!

Unread post by **KennyW** » 16 Nov 2009, 23:50

Hi Mike,

I have done nothing to the pump tonight apart from get the cold chisels resharpened.

On your Dremel what attachment did you use to cut the slot in the security bolts.

Kenny.

MikeT · Unread post by **MikeT** » 17 Nov 2009, 15:04

I'm using a diamond cutting wheel. It's slow going as the armour is much stronger than the bolt heads. I wonder how BOSCH/PSA intended they be removed, especially the recessed ones so as not to damage the armour?

Unread post by **CitroJim** » 17 Nov 2009, 17:20

Pukka dealers have a drilling guide plate Mike and then use something akin to an "Eezi-out" to extract the bolts.

I have a diagram of one somewhere...

MikeT · Unread post by **MikeT** » 18 Nov 2009, 14:00

I have never had success drilling then using easy-outs so avoid that strategy wherever possible. Perhaps with the right power tools I might have more success but until then, I'll always look for alternatives and in this case I feel redeemed as cutting slots means I can re-use the bolts

Any such diagrams and info you have on these pumps is always welcome Jim, I can't emphasise that enough though I do realise just how busy you are and feel guilty having to ask for yet more favours.

Unread post by **KennyW** » 18 Nov 2009, 23:10

Hi Mike and Jim,

Success armour removed and hollow pin removed much less painful than the last time.

<a href="http://s632.photobucket.com/albums/uu41 ... G_1084.jpg" target="_blank"><img src="http://i632.photobucket.com/albums/uu41 ... G_1084.jpg" border="0" alt="unscrewing security bolt"></a>[/url]

Mike great tip re the dremel quick easy and fast.

<a href="http://s632.photobucket.com/albums/uu41 ... G_1089.jpg" target="_blank"><img src="http://i632.photobucket.com/albums/uu41 ... G_1089.jpg" border="0" alt="Hollow pin removed"></a>

Unread post by **KennyW** » 18 Nov 2009, 23:16

Here are some pics of my armour and immob within.

Unread post by **KennyW** » 19 Nov 2009, 00:26

Hi Mike and Jim,

As you can see success, here are my thoughts.

From our experiences there are many forms of armour fitted to these pumps and security bolts.

I must thank you Mike for the dremel tip, it really does save time and money removing the bolts.

I have had time also to test the new solenoid in the pump whilst in the vice and it clicks away when 12v are applied.

My final test wil be to pass 12V through the wiring which connects to the immobiliser and the wire which runs to the solenoid in the car as this is where i believe the fault is.

Jim , I believe you rewired Lawrence 1973's solenoid because of a similar problem..

If no supply is found I am going to run a supply from the connector which fits onto the armourof the pump and run it direct to the solenoid.

Hopefully the car will start

I was hoping to remove the immobiliser and have it checked over by a friend who is an electronic engineer and likes a challenge but it's proving strubborn to remove.

Will keep you posted on developements.

Kenny