Replacing the injector pump seals

[imstein]

Hello All

So I've fix a fuel leak on the fuel injection system as described on the page and factsheet "Replacing Fuel pump seals (with pics) *DONT DELETE*".

All seemed well after the initial 2 hours of trying to access the rear blank plate. However on refitting the front plate with a new seal I initially got the van running again but with power loss. I decided to re do the front plate but I now can't seem to start the van at all....I may have put the shims and springs back in out of order as these dropped in my hand when removing...so I didn't see them in situ, I've just done the best guess.

I'm wondering if anyone has any idea about the order (or has a picture) correct order/fitting of the spring and shims when Replacing the injector pump seals.

Help please....I'm off to Germany in her for Christmas!!

Thanks

Nick

[helen&tony]

Hi Nick
Send me your e-mail addy in a P.M. and I'll forward an exploded diagram of the pump to you!
Cheers
Helen

[helen&tony]

Hi Nick
You have e-mail
Cheers
Helen

[Simon Jones]

Does this cover it? http://www.igmaynard.co.uk/bongo/member ... elpump.pdf

[Northern Bongolow]

it is quite common for them to start and stall, or not start at all after you have done these seals, some have a primer on the top of the fuel filter housing that can be pushed down to help it prime, later models dont have this.
i usually have to crack the injector pipes or even crack the center nut (odd shaped tool needed/to be made.) on the injector pump outlet to get them to prime properly. sometimes if you rev them quite hard straight after doing the seals you can get them to run through the lumpy stage, but not always.
if you crack the injector pipes to bleed, cover them with a cloth or you may spray the inside of your bongo with fuel.

[Simon Jones]

Just a thought, it is worth a squirt of Easy Start to get the engine running which will hopefully pump the diesel through?

[TonyW]

Hmmmm ...... just had a diesel leak explored by my local mechanic and he's of the opinion it's a leaky injector seal so this thread is very relevant ...... however being pretty much non-mechanical the process on the sheet looks a bit ..... well ..... tricky.

Imstein how was it for you? 2hrs or perhaps longer?

Thanks in advance.

Tony.

[mikeonb4c]

Hmmmm ...... just had a diesel leak explored by my local mechanic and he's of the opinion it's a leaky injector seal so this thread is very relevant ...... however being pretty much non-mechanical the process on the sheet looks a bit ..... well ..... tricky.

Imstein how was it for you? 2hrs or perhaps longer?

Thanks in advance.

Tony.

I failed dismally at this job and did my back in in the process. Even Adrian at Japandirect, who I handed the job over to, insisted on removing the pump to do the more awkward one, and I was happy to pay. Life's too short. Unless you have smallish, skilled hands, a good back, good eyesight, great patience, and a measure of luck......don't bother! Of course, those who've managed it love to be blase and say how easy it was but.......

[helen&tony]

Hi Mike...
Of course it was easy....Tony did it for me
Cheers
Helen

[imstein]

Thanks for your responses.

We'll the changing of the seal job in itself was horrible...not too technical it's just the rear seal on the blanking place is is a horrible position and even with my small hands was tricky to get to. Could only manage an 8th of a turn with the spanner each time..no room for hands and a tool...could not even get my scocket set down there. drew blood even...grrr..

Front seal was much better but was unsighted when the springs and washers came out in my hand. However both seal were changed and it's all back together and the leak is fixed. leak was that rear blanking plate seal.

However as my problem is now the restart. I'm on my second day of charging the van after failed restarts and it's currently on charge (at night in the rain, great!)and will try the suggestions on Injector pipes and see if I have a bleed option on the 1996 bongo.

Tony...Seal took 2 hours to replace but I've spent 3 times that now on restart....I did get her started after 1st go at seal the change but had massive power loss so decided to re do front spring setup. After which I can't restart.

Northern Bongoolow...yes I did get restart but with power loss....I'll see if there is a primer.

Thanks all for your comments...I've got another hour of recharge to go and I'll have another try.

If no good can anyone give me an idea of a bristol bongo garage to get her to? I tend to alway do DIY fixes so I don't have a regular garage in area. This time I'm a little stumped.

I'll let you know updates when I can.

Cheers

Nick

[Bob]

ADS

http://www.bongospecialists.co.uk

Been using them for some while.

[imstein]

Hi

So the bongo is back up and running.

Constant turning over of the engine failed to achieve restart result and I was reluctant to crack the fuel pipes to injectors.

After some discussion with a friend from Airbus who works on their fuel systems we were certin that air in the injection pump was stopping fuel be drawn into the pump via the fuel lines, so I undid the input fuel line banjo connection and manually filled the botton of the injection pump with new fuel, it would only take about 20-30ml untiil overflow so I then needed to crank the engine for a split second and this drew the 30mls into the botton of the injection pump proper, this was repeated until I think I had about 150-200ml in.

Then I backfilled the input fuel line between the fuel filter and the injection pump to try and limit any air pockets and re connected. Then finally I undid the out fuel line from the pump (the return fuel line) and 'sucked' with a drinking straw the remaining air from the top of pump. The out fuel line sits higher on the pump than the in fuel line, so therfore sucking air from the top 'draws' fuel into lower part of the pump via the lower input line.

Reconnected the out fuel line pipe and she started almost straight away.

She's running OK but I still have a loss of power, certainly above 2500 revs is a bit flat, maybe an air pocket still?? I was wondering if something else is wrong somewhere, anyone got any knowledge about how a failing turbo shows itself?

Also once again thanks for all your advice and offers of help..I'm still booked into ADS in bristol on moday but at least I can drive there now!

Regards

Nick

[mikeonb4c]

Glad to hear there's been some progress. Many is the time I've looked at a Bongo and thought "Ya know, that vehicle really does have a lot in common with an Airbus."



But seriously, hopefully ADS can get it back up to 100%