Technical injector pump removal/possible overhaul

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Technical injector pump removal/possible overhaul

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Mar 5, 2013
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Location
France, Autun
so, i have a small fuel leak. enough to leave unsightly embarrassing rainbow puddles whenever i park anywhere. i think i have narrowed it down to somewhere underneath the injector pump, either from the pump itself or from a delivery line somewhere, i have felt around and can't feel any oily wetness from the high pressure lines so i assume they are alright.
so next chance the weather gives me, i shall be removing the pump, annoying thing is i changed the cam belt last weekend, seems i shall be doing it again! :bang:

do any of you experts have any particular advice for me with regards to keeping the timing during the leak hunt? changing the belt alone was fairly easy as i just kept the sprokets in the same position, and swapped over the belts, this time, there is more risk of things going wrong

i've probably forgotten to mention something but im tired and off to bed.
thanks in advance
 
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tip ex on the belt and sprockets trick was exactly how i did the timing belt, i was thinking more in relation to the injection pump timing once the sprocket as come off the pump, i think from looking at the workshop manual, there is a notch in the sprocket which corresponds to the pump in one position only, so the question would be:
is the worst case scenario that the pump will be 360degrees out or is it easier to mess up that that? and if it is out, how badly will i damage the motor?
i've seen some videos where the flywheel has to be N degrees past tdc and the timing marks on the pump lined up etc etc. all of which sounds like i would need specialist tools to make the job easy, which of course i dont have :)
also that the pump can be turned about it's axis somewhat thanks to an elongation in the mounting holes. will this be a concern on the TD100?
the weather seems like it might be acceptable to have a go this weekend.
 
small update, the pump has been doing my nut in the last few weeks, i've been losing power and the start up has been more and more rough and smokey (could be another separate problem lurking) and even when warmed up, the exhaust smells acrid and i get puffs of white smoke, and even though idle is not completely rough, im sure that she's only running on 3 cylinders most of the time, not good.
I managed to get the pump out last weekend, but no joy on finding the leak, the whole thing was covered in diesel and it wasn't just a single seal which had perished, the thing needs an overhaul, and that's not a weekend job for the inexperienced. so annoyed i had to put the damned thing back in unfixed :(
so today i dug deep into my pocket and bought a second hand pump from the scrappies, cost me £125 with a 3 month guarantee, but i have no idea of the mileage. the thing has a thick layer of dust over it, but looks very clean on the underside, almost like it has come from a write off with low milage, and has been sat on the shelves for a fair few years. hard to say though.
if it has been sat on the shelf for a while, am i right in thinking that the seals perish faster when not lubricated?
either way, all shall be revealed this weekend when i fit it, i'll be nice if it all goes well, and i get the lost 40hp back, i don't even feel the turbo anymore, it spins up but does nothing, getting overtaken by waggons on acceleration is embarrassing and acceleration that slow is dangerous when joining the motorway.
while im at it, i might take out all the peices blocking the glow plugs and trace the flashing glow plug light problem, i hope it's not the control unit.
 
SEALS may be an issue.. BUT you may as well try it as is..,

glow plugs are likely to be carp connections stopping the current getting through..,:(
but worth disturbing stuff anyway..!!, ;)

keep meaning to ask.. where is La Garnache -- ? -- I'm fairly well travelled,:eek:


done Lozere + Ain :D

Charlie
 
Cheers for your comments, as usual, sound advice. always appreciated
La garnache is in the vendee, about half an hour from Nantes in the north west of the country https://www.google.co.uk/#q=vendee
it's a nice little area, with the littoral (marais in french) somewhat reminiscent of the fens in norfolk, very nice, if you like that sort of thing, but otherwise it's very flat, dull and featureless if you don't. the vendee is very sparsely populated and has a couple of towns, La roche sur Yon with a population of about 60k, which was (according to wikipedia) named the dullest town in france in 1854 (not a lot has changed there) and Challans with about 20k. due to the clay bed being belo sea level and the are being salt marsh, the region was very important when salt was an essential commodity in Europe, much of the advanced worlds salt came from here and the tradition is continued mainly for the tourists. it is damned good salt though.
the beaches in between Noirmoutier and La Rochelle are outstanding, with silky fine sand warm water. La garnache is in the north of the region, right on the border of Loire Atlantique about 80m above sea level and about 30 miles inland, near the region's 2nd town Challans.
i do love the south of france, but it's just too hot from me, i love even more the mountains, but the Mrs doesnt like the cold or heights :(
did you go acros the Milau viaduct when you were in Lozere? it's incredible.
 
flat = boring.. ; - }


I live on the "Berkshire downs",
and have spend most hols , etc in Welsh, French Cumbrian mountains,
in the UK I don't do "beaches" , but the French have PROPER SAND , and nobody there.., so they are FINE..!!,



stayed @ Boyardville , in the south of your region.. so must've driven by fairly close.. in my Marea..!!,


Charlie
 
royal pain in the arse weekend. :bang:

the short version is that the pump from the scrappies doesn't work.

my first attempt, i brought trouble on myself, like an amateur i neglected to change over the stop solenoid and the control unit from the old pump. in the process of bleeding the lines and trying to figure out why it was not working, i drained the (apparently already weak) battery flat (n) so that put an end to saturdays attempts, we had guests the evening so it didn't slow me too much.

Sunday brought about the change of the control unit and the stop solenoid, this time i made sure i tested that it all worked before assembling and trying it, plunger descends into the unit, allowing fuel to pass, very good, put it back in, try again, nothing. maybe i didn't bleed all the air out the system properly? crank it again, nothing out the injector lines at all. i took the pump back out again, and put the old and new side by side, stripped bare, both with the plunger from the stop solenoid removed so as to allow fuel to pass without current to the pump. watch the video for what happened. the second hand pump is doing NOTHING.
http://www.youtube.com/watch?v=E_MyFV35Chk&feature=youtu.be
i took the front plate off to verify that there was fuel int the fins, which there was, but nothing was passing out the injector lines. i don't know enough about injector pumps to try taking the thing apart and finding the problem, and there is a 3 month guarantee on the piece, i shall be taking it back.
in the mean time i ran out of weekend and had to rush the old pump back in before it got dark, i stopped before it was all nice and tidy in the bay, i have vacum tubes undone loose, oil rebreather and fuel filter unattached, diesel everywhere, so i shall have to take the wife's xsara picasso to work tomorrow :cry: horrible car. good job she's off work pregnant however, don't fancy paying to hire a car for a week. when i get back from work i will have about an hour of good daylight to finish of the tidying up and refitting of the marea.

i'm getting sick of loosing every weekend like this, i'd much rather be running around a park with the little lad. :(
 
aside from all that, i managed to get access to the glow plugs, with injector pump and oil rebreather out the way, it was quite easy. All plugs become incandescent within 5 seconds of direct battery contact. it seems the flashing glowplug light after startup might be to do with the control unit.....
 
aside from all that, i managed to get access to the glow plugs, with injector pump and oil rebreather out the way, it was quite easy. All plugs become incandescent within 5 seconds of direct battery contact. it seems the flashing glowplug light after startup might be to do with the control unit.....


in all of the 20+ I've changed only 1 was a DUD the otheres all still glow fine.. so it's down to poor connections in my book, :(
screwing everyting back together may well do the trick..,
the marea I had ( jtd) stopped flashing after the plugs removed + put back..,
charlie
 
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