bosch body armour removal

Post by **KennyW** » 05 Nov 2009, 20:38

Hi Gang,

Message in particular for CitroJim and MikeT,

The long security bolt on the body armour, exactly how did you remove it

This is my idea

partially drill the bolt and then mark a slot across it. take one hammer drill and masonary bolt in fit into slot and rewind the bolt out

Any thoughts. 8)

Kenny

Post by **CitroJim** » 05 Nov 2009, 21:37

KennyW wrote: The long security bolt on the body armour, exactly how did you remove it

With great difficulty Kenny

That bolt in particular is as hard as nails and it was my father who found a method very similar to the one you propose

Good thinking!

Drill the head (possibly wearing out a couple of drill bits doing it) and then use a masonry drill in a big hammer drill running backwards. It works like a rattle gun!

Make sure all the delivery ports and other openings are well covered as lots of swarf will fly!

Good luck

Post by **KennyW** » 05 Nov 2009, 22:07

Jim and Mike your blogs re the Bosch pump are very accurate and detailed and if anyone is think of doing the same as myself I highly recommend them reading these first

The actual job is not hard but requires patience.

I will let you know the outcome.

Kenny

mark21td · Post by **mark21td** » 05 Nov 2009, 23:36

When I removed mine (it was a 406 pump so my have been differant) I managed to get it out with mole grips after grinding the head of and removeing the amour.
But as jim said you do need to cover ALL the pumps inlets/outlets as grunding dust will get in where swarf wont.
Once you have removed the armour you will find that it's a normal stop solenoied and nothing special.

Post by **KennyW** » 07 Nov 2009, 19:37

Hi there,

Here's the latest, the second security bolt came off relatively easily

and part of the armour was off then came the next problem

.

Over the stop solenoid there is also armourwhich is secured by a hex screw (removed) and on the other side is a small hole with a cylinderical hollow pin this is refusing to budge.

I thought this would simply split apart

as it is split dwon the middle. I have a replacement with my stop solenoid purchased earlier hence i know what it looks like

Any suggestions on removing it

My method was to use the split to separate and reduce the diameter and extract from hole as all my drills for the size of hole have been blunted with use.

This my be the only way for it to be removed: Drill it out.

Kenny

Post by **CitroJim** » 08 Nov 2009, 07:00

Ahh, you have the later, more tricky one Kenny. I've no personal experience of this one but if you have a natter with Lawrence1973 down in the Peugeot part of the forum, he has...

I think a Dremel may be needed here.

MikeT · Post by **MikeT** » 14 Nov 2009, 13:55

Can you please elaborate more on the strategies you employed as I'm starting on mine now.

The first two seem easy enough - cut a slot and screwdriver them out - but the other three are recessed/shrouded.

Is it a case of drilling them out to create a bowl seat for the masonry drill to fit into? Any other tips for ensuring this method will work?

Post by **KennyW** » 14 Nov 2009, 23:29

Good Evening Mike,

Where exactly are you on the removal of the armour?

All the bolts I removed apart for the 2 security were no problem.

The 1st security bolt came loose with several strikes with cold chisel and hammer.

The 2nd bolt took a little longer but the same method.

I thought of the idea cut a slot in the head and using the reverse setting on a drill take a masonary drill with their type of head and unscrew the bolt out that way.

But on my pump I did not need to do that.

The small hollow pin , if you have it, screw in a strong self tapping screw, place mulgrips onto screw tap out. this was suggested by lawrence1973 on the peugeot forum and confirmed by a mechanic in Lawson diesel.

I shall be removing my pump tomorrowas the weather is suppose to better in this neck of the woods.

Kenny

MikeT · Post by **MikeT** » 15 Nov 2009, 11:27

Seems there's a lot of differently configured VE pumps for different cars... here's another one. It has five sheared security bolts, the lowest two are exposed while the other three are shrouded.

The exposed pair were slotted and driven out with a screwdriver easily enough.

Post by **KennyW** » 15 Nov 2009, 18:04

Hi Mike,

This is different from my pump as I only have 2 security bolts and the armour covering the stop solenoid is different.

I have some photos taken today and I am going to try and attach them

Kenny

Post by **KennyW** » 15 Nov 2009, 19:41

Post by **KennyW** » 15 Nov 2009, 19:44

Sorry there's no text but I don't know if i did it right

I hope the photo's help

Kenny

Post by **CitroJim** » 15 Nov 2009, 20:10

That do Kenny

I've replied more fully in Mike's pump blog...

MikeT · Post by **MikeT** » 15 Nov 2009, 20:13

I got all but one out so far - not sure how to tackle it (my dremmel needs a recharge anyway). It's the one, like yours Kenny, that sits too near the upper delivery valve. Your shroud, did you cut some away and how did you remove the bolt?

Post by **KennyW** » 15 Nov 2009, 20:52

Hi Mike,

I managed to remove mine with a cold chisel but like you it's blunt now and needs sharpening.

I think the dremel will get in and cut the necessary slot and it will be removed.

I'll take the chisels to a mechanic friend and egt them sharpened.

I think he has a dremel as well so I'll ask him nicely

Kenny

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