General Multijet hp fuel pump

[tinmar49]

The bad news I had today is that the high pressure fuel pump has a leak. I hadn't noticed any smell of diesel or had the oil level increasing, but after taking off the airfilter, the wet pump is obvious.
The MOT tester spotted it, fuel is wetting the gearbox housing.
It looks like I will have to put the car on a SORN.

The good news, if there could be any, is
1 The pump is one of the more accessible bits to work on.
2 I already have the replacement for the Panda, a 1.7 cdti Corsa.
3 The cost is likely to be under £300 for an exchange unit from Germany, I was quoted £500+, not including labour, which is too big a fraction of the value of the car.
4 Apart from that, there was nothing else wrong with the car.

 

[notsmartcars]

Just looking on eBay seal kits £20 ish

 

[tinmar49]

Thanks, I had no idea that seal kits existed, I will check compatibility. I have no idea how easy it is to dismantle, apart from the leak, the car is going fine.

 

[Wee Smurf]

There are places that refurbish them and put in new seals if you don't feel up to the job. Mine went just over a year ago. It would be silly money to get even a refurbished one from Fiat. I ended up just getting a used one from a scrapyard for a fraction of the price.

 

[tinmar49]

I will take a chance with the seal kit, even though the part numbers don't seem to tally. The ePER only gives one p/n 46779630. This pump is common to so many models/makes that the seals are very likely to be ok.
I will buy a new high pressure pipe to the rail, p/n 73501326.

 

[Wee Smurf]

When mine went, it went in style. My car literally wee'd itself in the car park. There was no sign of any leak at home in my garage at all. Luckily it was close enough to the dealer and they let me supply my own secondhand pump.

 

[tinmar49]

I've just got the kit of seals from Diesel Components via eBay'*
I took off the air filter, degreased the pump with brake degreasing spray, dried it all off with my airline, and started the engine.
The leak*is from the upper rear high pressure cap, just a small one, approximately 1ml per 2 minutes, enough to build up and make a mess.

 

[buttonsandzips]

Mine was leaking which caused it to fail the MoT. My 55 plate sporting is on 95K and otherwise in good condition so I had it replaced with a refurb. Was £400 all in.

 

[tinmar49]

Got the pump off just as the rain started this afternoon. The vacuum pump has to be moved slightly to expose one of the screws for the hp pump.
In my hurry, I disconnected everything before remembering that I was going to collect some diesel in a clean container by using the fuel tank pump with the ignition on for a few seconds.
The tank is full, I may be able to syphon some.

 

[tinmar49]

For those of you*who would prefer to play it safe and get a professionally rebuilt pump, the German eBay site of "einspritzpumpen" has the most competitive price of £249+£12pp and are open to offers.
eBay no. 272351414579

 

[Wee Smurf]

As I supplied the pump, I still have my original pump that I can refurbish if necessary as a later date.

 

[tinmar49]

I have completed refurbishing the pump except that the cylinder head screws havn't been torqued yet.
The o ring kit had some extra seals for a variant, which are not used. I was a bit worried at first by the gap under the heads when they are done up. The 1mm gap is intentional. When the crankshaft is withdrawn, two plungers and a very fragile spring fall out. I was lucky not to damage the spring. To avoid this possibility you need to remove a circlip which is down the fuel inlet port first and get the three parts out before taking the crankshaft out. The circlip is only about 6mm diameter and the tips of the circlip pliers/ strong tweezers must be 0.5mm approx.
The shaft seals are identical and run back to back, garter spring sides away from each other. You need to press the first one fully home and the second flush to leave a gap. There is a drain hole between the seals which prevents diesel getting into the engine oil and vice versa*

 

[notsmartcars]

Fingers crossed its a good result for you

 

[tinmar49]

Got it up and running today. I checked that the new hp pipe was the right one before cutting the old one in half, cleaning up the cut end and washing it. I fitted it to the pump outlet with a length of hose to a container.*Turning on the ignition starts the fuel pump in the tank to flush through the hp pump. I also turned the engine over with*starter motor to fully flush the hp pump. After running about 1 pint through, I connected the hp pipe from the pump to the common rail and the engine started first time. No sign of any leak, I will book up an MOT tomorrow.

 

[koalar]

Well done

 

[tinmar49]

Passed its MOT today, I have booked it in for its official yearly service and then its up for sale.