Not starting following replacing Injector pump seals.

[Colyn]

I am hoping that those of you with experience of this operation will be able to advise me where I have gone wrong.
Having followed the factsheet I have replaced the two seals front and back of the injector pump. Incidentally the Mazda dealer didn't sell the seals but the local injection specialist did.
I've now replaced them but can not get the Bongo to start again. It turns over fine but appears not to have any fuel to the injectors. I have checked the banjo and fuel filters. It is the self priming type. It ran perfectly before this work apart from the drip of diesel.
I have searched the forum top to bottom and despite many posts seemingly going to provide the answer none has.
I can only suspect that I have reassembled the parts incorrectly or in the wrong order or that I have lost a small part.
In addition to the two springs and two shims as mentioned in the fact sheet I had two other parts, one looking like a 4mm dia. pin with a large washer fitted to one end.This has a machined groove cut near the opposite end to the washer. The other a thin walled hollow tube partly closed at one end into which the previous part fits.
Having refitted these parts as I thought they came out, no success. I undid it all again to check the seals had not moved, it still wouldn't start. Taking it apart again to turn the pin thing around still no joy. Could it be that the groove in the pin should have an O ring fitted and this fell out unnoticed?
Having discharged three batteries can any one explain how it goes back together properly so when the batteries are recharged I will be able to drive to work again?

[francophile1947]

My knowledge on this is very limited so I could be talking rubbish (shut up DBO ), but did you actually remove the pump to replace the seals? If so, it may need re-timing.

[Colyn]

Thanks Francophile but no it was all done insitu I have all the scars to prove it.

[Tripewriter]

OK you have air in the system are you running on diesel or VO is there any kind of a conversion been done?

[Tripewriter]

Hmm Just read your post again!! The 4m/m pin? where did that come from?

On the side of the pump nearest to you, you have the springs with shims in the top hat and at the top of the spring what looks like a 10m/m bottle cap with a 5m/m hole in the centre. this sits with its base on top of the spring with the sides of the bottle cap going in first.

Was this assembly the problem?

[rita]

Hi Coyln,

I don't think the tube should have come out,I think it should be held in place by dowels or the like.There might be a pump diagram kicking about.

Best of luck.

[rita]

Hi Coyln,

I don't think the tube should have come out,I think it should be held in place by dowels or the like.There might be a pump diagram kicking about.

Best of luck.

Hi this should help.http://homepage.ntlworld.com/mike.gough ... iagram.pdf

[fatcatlawyer]

When mine were done, it took ages to get the fuel through to the engine, in the end we filled up the fuel line with oil and then it started atraight away. Try bypassing the filter, and put some fuel in the line to the injectors.
ian G

[Colyn]

Hello all,
thank you all for your suggestions so far.
Tripewriter said

Hmm Just read your post again!! The 4m/m pin? where did that come from?

On the side of the pump nearest to you, you have the springs with shims in the top hat and at the top of the spring what looks like a 10m/m bottle cap with a 5m/m hole in the centre. this sits with its base on top of the spring with the sides of the bottle cap going in first.

My descriptions are probably not the best it would be better if I knew what the parts were called.
However his bottle top described one of the parts I was querying and I had that the wrong way around.
The pin thing the washer (round plate) end fits into the bottle top and goes into the pump before the bottle top, I think?

I tried the bottle top as Tripewriter suggested but still not running but maybe it is the pin thingy that is now wrong?

Rita sent a pdf of an exploded view of the pump excellent I thought this will definitely show me what's what, but the parts I am referring to do not feature?
They should be shown between part 31 & 41 being assembled inside 31 ahead of 41 the spring and the other spring and shims.

I would still like to know that I've put it all together the right way before I try looking for other possible causes of not starting.
Again thanks for the help so far. I feel at least I am getting closer to a solution but still need that vital piece of information.

Colin

[Northern Bongolow]

thanks for that rita,thats a good post from my point of view,lets me see exactly what to expect,combined with dandys post,i now have the complete picture,
thanks again
regards ady.

[Tripewriter]

Hi Colyn, I am fairly sure that pin and washer should not have come out! However if you can get it back in treat yourself to a a "hand-primer" around £6 from any decent motor factors and draw the fuel through by attaching the suck end of the primer to the connection on top of the advance unit, pump until you have a bubble free flow of diesel. The system is then fully primed, if it still doesnt start. You need a pump expert.

[Colyn]

Hello everyone,
Thanks for all the helpful suggestions.
Having put the parts back in place I was still not getting the bongo to run.
Self priming was not working. I disconnected the fuel line from the filter put a small funnel in the end lifted it up so it was above the injector pump and poured diesel in. The level slowly dropped as I added more diesel. I then disconnected the return fuel line and I could see bubbles brusting at the end of the metal pipe. Eventually the diesel appeared at the end of this metal pipe. I tried starting and it ran until the diesel ran out. I repeated the whole process this time turning the engine off just as the funnel was empty of fuel I then reconnected the hoses. Starting again the engine ran and has been fine since.
Thanks again for the assistance.
Colin

[mikeonb4c]

Hello everyone,
Thanks for all the helpful suggestions.
Having put the parts back in place I was still not getting the bongo to run.
Self priming was not working. I disconnected the fuel line from the filter put a small funnel in the end lifted it up so it was above the injector pump and poured diesel in. The level slowly dropped as I added more diesel. I then disconnected the return fuel line and I could see bubbles brusting at the end of the metal pipe. Eventually the diesel appeared at the end of this metal pipe. I tried starting and it ran until the diesel ran out. I repeated the whole process this time turning the engine off just as the funnel was empty of fuel I then reconnected the hoses. Starting again the engine ran and has been fine since.
Thanks again for the assistance.
Colin

Great news - we ought to add that to the relevant factsheet so as the next person can avoid the hassle you had