1.9TD fuel pump swap now non starter

[CitroJim]

No, the immobiliser module will swap over as although they work differently, physically they are similar as both straddle the stop solenoid...

[xantom]

Thanks Jim. Next question; I've removed all the torx bolts I can see that hold the biggest armour plate on. I'm left with 2 strange looking things, can only describe them as plugs sat onto thin shafts and they're clearly there to make removal difficult. Are these drillable and if they are what do i replace them with. they're on the non-leaky pump too.I've taken pictures and if i can see how to attach them I will. Nope, can't figure out how to attach photos. They're on the pictures on your pump seal change guide.
Tom

[CitroJim]

Yes, Those are the tamper-proof bolts. They can be drilled out with a bit of difficulty. They are very, very hard and you need some bloody good drill bits to do it.

One measure of success I've had in the past is to bore a shallow hole with a normal drill and then get a slightly larger masonry drill running backwards with the drill set to hammer and this will often then shock the bolt loose.

You must replace them with similar Torx bolts to the others. length and hardness is critical... You can sometimes borrow them from another pump.

One vital thing is to always keep at least two bolts tight in the distributor head at all times, ideally on the diagonal. The pump piston can break if the head moves out and falls sideways...

My Wiki article will give some guidance...

EDIT: One other critical issue is to ensure no swarf from the drilling operations get into the pump - seal all orifices...

[xantom]

Thanks. Here we go. Maybe have to go out and get some better drill bits. Got a couple of appropriate drills and my son works in a local factory that specialises in all kinds of bolts and connectors for all types of cars. About time the flow of goods and services was reversed.
Tom

[MikeT]

IIRC I think my solution was to cut a slot in the heads and use a screwdriver. I think I took some pictures and posted them in my blog when I attempted my first pump rebuild.

[CitroJim]

Trouble is Mike, some of the difficult ones are too deeply recesseed to allow that...

[MikeT]

Trouble is Mike, some of the difficult ones are too deeply recesseed to allow that...

I found cutting through the recess didn't cause any issues either

[MikeT]

Example on non-recessed bolt but you get the idea. It's the size of the tool (small diamond encrusted cutting disc) that helps

[CitroJim]

That tool looks just the job Mike

[KennyW]

The dremel is the tool that's what I used.

This strangely reminds me of my pump isues a few years back.

[CitroJim]

This strangely reminds me of my pump isues a few years back.

I remember that well Kenny

[KennyW]

Xantom,

If you search far enough back october november or december 2010 you find lots of reading re bosch fuel pumps and armour removal by MikeT and myself with lots of contributions from Citrojim and other members. Worth a read for info and a good laugh.

[stupidxantia]

IIRC I think my solution was to cut a slot in the heads and use a screwdriver. I think I took some pictures and posted them in my blog when I attempted my first pump rebuild.

Tuning my AS3 pump required removal and de-armour to access the fuel screw and needed some general maintenance work at the same time!
I used the same method, cutting slots in the anti tamper bolts and removing with a screwdriver. I was astonished at how loose they really were after slotting the heads!

[xantom]

Thanks guys. Had a hell of a time getting to the immobiliser units on both pumps. The control units are of slightly different design as were the rear mouldings of the pump body they abutted. Had to slightly adapt the immobiliser electronics casing to fit. Also had to swap over the solenoids as they had different electrical connectors on top. Nothing's ever simple, is it. Bad news is that after fitting everything back on I get the same immobiliser fault. Engine turns energetically without starting and the wee key in a box symbol just flashes away. The sensor on the key stalk works of course. I've bought a Lexia kit over the internet but having trolled through the forum I'm a bit nervous that I've maybe bought a pup. I'm just about to try installing it on my laptop, fingers crossed. Any clues now, without a computer diagnoses ? Checked the fuse for the Pump ECU too.
Tom
Ps can anyone point me to a guide on how to attach photos to posts?

[myglaren]

Picture posting guide.
Can't help with the immobiliser woes unfortunately.