Help please leaking diesel pump- not seals.

[jassani]

Hello and Happy new year to you all.
I am currently having issues with a leaking diesel pump, I have replaced the seals as per the bongo fury fact sheet and they are now sound with no leaks. I am still seeing a drip of diesel which is worse when the engine is cold. having checked the back seals and front seals with a mirror they are as I said dry with no leaks, the drip appears to be coming from the bottom of the pump from a threaded hole. The threads in this hole are very clean and it looks like I have lost a blanking bolt, could somebody please check there pump and tell me if the threaded hole is blanked and if possible the size of the bolt that's in it. ( when looking at the bottom of the pump with a mirror there are 3 threaded holes) I have tried looking at the pump diagram but the bottom of the pump is not shown. The bongo is a 1995 friendee.

[Northern Bongolow]

i have 2 spare pumps on the shelf, both runners, they both have 3 threaded holes underneath with no blanking bolts fitted. they dont appear to need any as they look like mounting bolt holes. they are not drilled through to the internals of the pump.
there is no other point underneath that anything could leak from so the leak must be from either the advance side seals which it sounds like you have just done or the main seal on the block where the injector pipes screw to, or the front seal on the end of the shaft, this is hidden from view as it goes up against the plate then to the pump drive gear at the front.

does it leak worse when you rev it up then let off the throttle, if so, it sounds like the side seals you have just done.

[jassani]

Thanks for your advice northern bongolow you are correct the 3 threaded holes are not blanked, i was worried the pump housing was cracked and was leaking from this hole. upon further inspection i have found that it is infact leaking from the main block with the injector pipes. i have searched for a gasket for this with no joy and then realised that it is infact a seal. i have found a seal repair kit online for £27 and better schematics of the pump stripped down. the question is can i strip this main block off while it is on the van to replace the seal or will it require the pump off and a full bench strip down and has anybody done this before?

[Northern Bongolow]

you can replace the large O ring here without removing the pump from the motor.

mel, the great pretender describes how to in this thread.

http://www.igmaynard.co.uk/bongo/forum/ ... er#p586477.

the pump is a copy of a bosch unit so find a good bosch agent who will have the proper part.

[rita]

you can replace the large O ring here without removing the pump from the motor.

mel, the great pretender describes how to in this thread.

http://www.igmaynard.co.uk/bongo/forum/ ... er#p586477.

the pump is a copy of a bosch unit so find a good bosch agent who will have the proper part.

I think you will find that Mel infact removed the pump, this is not the run of the mill DIY job even with the pump removed.

[Northern Bongolow]

thanks for that rita, i must have misunderstood how mel did it.

[The Great Pretender]

I had the pump off as the cam belt was being changed; I also wanted to replace the front seal as I was certain it was drawing air in.
Can the rear large o ring be changed in situ? Probably, try it BUT don’t loosen the injector block any further once the o ring is exposed.
Good luck…………….

[Northern Bongolow]

bu$%er
mines leaking at the large O ring at the high pressure end where yours was mel, thinking i could just replace it while on the motor i chatted to lawsons diesels, they said dont split it when on the bongo as there is a small disk at the plunger head that will move out of position. its ok to split when removed and upright on the bench as the disk will stay put, but it still may break off a little peg which acts on the plunger assembly.
now call me a pratt but i thought i would check this out for myself------------------.
i have several spare pumps so thought i would check it out on one of these on the bench, and what lawsons said is true . thats now in a million pieces in a bucket .
ive got a pump that ive done the side seals and the nose seal so im going to bow to the great guys at lawsons and send it up to them for the large seal and the top seal and full test on their rig then swap over.

THATS THE LAST VEG OIL THAT GOES IN MY BONGO. .

[The Great Pretender]

Interesting information, I did one on Friday at Wheel Quick for one of the lads. I’m not surprised that the pumps are beginning to leak lets face it 17 year old O rings that operate from around 0 to 80c get tired. Got a spare set of injectors? Worth getting them reconditioned too.
And don’t tell porkies………..there are only 852979 parts.
Worth a repost.

http://www.brick-yard.co.uk/forum/ve-in ... 17456.html

[Northern Bongolow]

thanks for the great link mel but the bucket and its 850000+ parts are going to lawsons .

i like the bit where the builder in the link keeps re-doing it cos he drops the springs . ive got no chance.

just wondering if the pressure nozzles to the injector pipes or one nozzle fails on the outlet high pressure side, would that allow pressure to build up inside the outlet head causing the large O ring to leak. .

[corrour]

Mr northern bongolow sir.
My bloody pumps leaking now looks like large o ring seal.
Have you any spares left ?
I can ring you later if ya want.

Thanks mate

John
Purveyor of Quality part worn winter boots & bullshit.......

[Northern Bongolow]

from mels link above, pics 3-4-5 mate, as per our phone conversation.

[corrour]

Thanks Pal
As soon as it stops bloody raining.

I will keep u posted.