Bongo Fury

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From: [email protected]
To: [email protected]
Subject: diesel pump seals replaced but can't start
Date: Fri, 13 Sep 2013 12:14:31 +0100
Having replaced the pump seals as per the fact sheet my van will not start. The fuel filter is full but no diesel is getting to the pump.
I couldn't put diesel in the pump as per the fact sheet as I can't see how it can be done when the domed cover appears to be the lowest point and therefore it appears that unless you can put some in from the backing plate it seems impossible.
Another query is that when I took the domed cover off with its shims and springs the collar in the pump came out and I am not sure which way round it sits against the spring. should it be the flat lip of the 'collar' against the spring or the unlipped end, and would it make any difference. I have tried it both ways to no avail.
When I took the backing plate off to replace its seal the plunger/piston which hits the back plate was flush with the rear end and seemed to have little or no movement when pushed, is this normal or does it suggest a seizure?
Cranking the engine is drawing no fuel through, is there a lift pump or some sort of manual system to get fuel into the pump?
My van has been unstartable for 5 days and I am presently on a remote part of the Isle of Lewis and the nearest garage is 35 miles away.
I am happy in the knowledge that I managed to replace the seals myself but am now frustrated. Have I done something wrong or is there a simple solution?
Please help!!!

Sucking in air from somewhere maybe?

the piston feeling stuck is normal, this usually depends on the pump internal position when its stopped last, some have reported it all falling out so be careful dont try to push it either way.

make sure you have a good battery on, then get someone to crank the moter while you undo the pipes to the injectors, cover them with a rag so they dont spray fuel everywhere when the pump is (bled) of the trapped air thats inside the pump and pipes, nip them up again as the fuel shows itself at the injector tops.

some have a push button hand primer on the top of the fuel filter housing, but most dont. you could park the motor nose down hill, then remove the pipe to the filter from the tank and suck, then fit the pipe and crank the engine with the injector pipes cracked open.

this link shows the top hat.

http://www.igmaynard.co.uk/bongo/forum/ ... al#p129685

then have a read through this, it may help. click on the links in it too.

http://igmaynard.co.uk/bongo/forum/view ... mp#p596539