GrumpyGel
Well-Known Member
- Posts
- 26,490
- Location
- Christchurch, New Zealand
Do like a good saga... a good saga for the reader that is!just updating this saga ..
can't yet write 'solved' in the header as yet to road-test work .. no mot at mo. :-/
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anyhow .. last nov. decided to replace the hp.pump fuel regulator ..
sourced a genuine bosch regulator .. n started to dismantle bits 'n pieces ..
'n all went wrong .. mostly my fault ..
managed to round off the front starter nut and bolt ..
[ i should have used 6pt sockets .. not 12pt .. ]
but .. even with the specialist irwin sockets ..
i couldn't get enough leverage on bolt to budge it at all ..
in the meantime managed to undo the two regulator bolts ..
then .. another big mistake ..
as the regulator wouldn't come out by hand ..
i levered it out .. and in the process broke the regulator shaft ..
part of which remained inside the h.p.pump :-[[
so .. what to do ?
get it recovered to a garage .. possibly needing to replace the hp.pump
or persevere at home .. in the street ..
hoping i could get the starter removed and therefore get a good grip on the broken regulator shaft
'n hoping that could be pulled out without leaving debris inside the pump
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things got left .. as the weather weren't friendly fer working outside ..
' i had to come up with a starter bolt removal method ..
i ended up deciding to take a hacksaw to the offending nut ..
3 sessions with this hacksaw .. and suitable blade :
https://www.machinemart.co.uk/p/61-2in-mini-hacksaw/
did the job ;-]
starter motor removed without further fuss ..
broken regulator shaft came out intact using long nose pliers
[ rubber and nylon washers still in place .. nowt left inside pump ]
big sigh of relief ;-}}
'nother worry was that i'd dropped a metal hose clip
from off the hp.pump return lines ..
and thought it had gone down between pump and alternator ..
[ i.e. was it anywhere near belts n pulleys .. or jammed inside the alternator ?? ]
didn't hear it hit the engine tray ..
anyhowz .. turned out it had rolled to the right 'n was easily retrieved .. :-}
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so .. replaced the regulator .. with the new 'bosch' job
sourced new bolts for the starter ..
cleaned all electrical terminals and sensor plugs-sockets
refitted starter motor .. torqued up the bolts to spec.
re-assembled all pipes / hoses .. n topped up coolant ..
trickle charged the battery .. full after 7 hours ..
[ it had been sitting 8months .. neg. cable removed ]
refitted battery .. 'n ran the low pressure pump for 30 seconds ..
let it cool .. then another 30 second burst ..
checked for leaks .. then gave starting it a shot ..
after a bit of cranking it chugged into life n' settled down to a smooth idle
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took it for a short run on these back streets ..
all good so far ..
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gave a good clean out inside
pressure-washed the exterior ..
treated all rubber n plastic trim with armor-all
replaced all wipers ..
now ready for mot
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as for the original issue ..
well decided to replace the hp.regulator
as the 1st hp.pump replacement included a faulty regulator ..
that hp.pump were replaced as a unit [pump + regulator]
given all other fuel related main parts were replaced with new bits
i was wondering if the regulator was part of a faulty batch ..
hence decided to replace it ..
[ the dealership replaced hp.pump be of unknown origin
[ it certainly looks like a rebuilt job ..
[ unknown markings on the regulator
the bosch replacement regulator came from germany ..
looks to be made in czechoslovakia
as did my brand-new injectors
[ sourced from an lr independant garage .. ]
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has it solved the initial issue ??
no idea .. yet ..
[ the synergy-2a box 'n extra turbo controller have both been totally removed
[ IF all goes well .. i might consider getting it re-mapped ..
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on a positive note ..
on restart .. engine no longer acts like a wind-up toy ..
it jumps into life like it used to do prior to the 'issue'
and ..
mot now in better weather month .. as opposed to prev. winter time :-}
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and btw:
the 'new' injectors were sourced here :
http://www.ribblevalley4x4.com
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a.t.b.
`s`
Hope it performs well for you after all this agro!