Correct seals for the Zexel Bongo fuel pump

[dandywarhol]

Just got a couple of the correct seals from Lawson Diesel Injection in Edinburgh.
I'd a long chat with a very knowlegeable owner who has seen a few of these seals going and does say that veg oil can contribute to premature seal softening. (I know there'll be a backlash from one or two of the Welsh contingent about that statement )

Michael also recommend that the flat plate (which seems to leak most) should be rubbed down smooth with a sheet of EMERY paper and flat glass as the advance plunger wears the plate causing the seal to leak. He took time out to show me an example of a well worn plate.

Seals are £1.65 each and he'll post them out by letter post

[alphabetter]

Good info. Is there a part number or reference to get the right seal?

[richrich]

with a sheet of EMERY paper

I didn't click on it - that would be really dumb

[mikeonb4c]

Still nervous about tackling this job, but I did buy myself some O rings on Saturday at 50p each and they look suitable. Is there anything particularly special about the O rings then? Out of interest, anyone know if the flat cover (and the corresponding case on the injector unit not) have a recess into which the seal sits

[smartmonkey]

All 'O' rings sit in some sort of recess to locate them and prevent overtightening. It's not just the circumference thats important, you also need to make sure you have the right thickness of rubber. Check the ones you have will be thick enough to compress the right amount.

[mikeonb4c]

I'm hoping that hasbeen taken care of by the dimensions give out on BF by BongoNess i.e. he have internal and external diameters. I actually played as safe as I could by buying two different types - one type thicker than the other - to maximise my chance of having bought suitable ones. If, one removing the old ones, I find they completely different then I'll have to head out and buy some. Whats with the emery paper thing though - is it that, in order to get even compression - it matters that the mating surfaces are flat?

I'm actually very wary of doing this job SM - bad back, clumsy hands and ageing eyesight, etc. make this a potentially tricky one I think. I wonder if I might get a BF specialist like Adrian in Bury to do it but the question is, how much labour cost / time is it likely to be for a professional with the right tools. You'd think it would be quick but...

I'll try and give him a ring in the fullness.

[scanner]

with a sheet of EMERY paper

I didn't click on it - that would be really dumb

Well what ever it was that appeared looked REALLY rough!

[dandywarhol]

Maybe you're all too young to remember DICK EMERY

The seals are not conventional "O" rings - they have pressure "edges" on them and are almost square section, made by Bosch (Zexel are Bosch pumps made under licence) part number: 2 460 223 001 - 000

I wouldn't consider messing about with a fiddly job like it is with over the counter 50p O rings which will probably fail you Mike..................The part about the emery paper and glass surface is to "rub" down the plate and remove the scores made by the advance plunger battering off it.

I'll be tackling the job soon and take some pics.

[mikeonb4c]

That'd be great Dandy - I'll be really interested to hear your frank advice on whether newcomers should avoid this one or whether it is 'doable'. Also, whether the rings you take out are square section cos if so I'll bin mine. Not going through all that pain to fit dodgy O rings thats for sure.

The bit about bleeding the system after fitting will interest me a lot too. I'll have a read of my workshop manual meanwhile.

If your esitmate of professional mechanic hours to to the job isnt too high, I might get it done and save the pain of it.

Good luck

Mike