struggling with starting the latest Bosch conversion help

[Chug]

Oh dear I was hoping you had better luck in this feckin weather, have you loosened the 13mm bolts on the front of the pump pulley and tried moving it each way as afar as the slotted hole allows?

The pump pulls back because its just on the start of the camplate lift, but maybe its too adavanced if it pulls hard.

[bambi mk 1]

Give me a call when you are back at it tomorrow as I missed your text

[Mac1984]

thanks guys,

i wasnt sure if youre out at st paddys day bambi, so i just dropped you a quick message

The situation is like this:

the pump does not stay centered, it always tends to spring backwards. if i turn it more forward, it jumps into was seems to be the next injection position.
it does that likewise if i turn it more back. I have to hold it with a spanner so i can get the pin in, as soon as i let go, it springs backwards and sits tight against the pin, so hard i cant get it out accept with a plier and some wd40.

So i put on the timing belt, then tried to move the pump along the slots after loosening the 4 bolts, but then it pulls very hard on the camshaft. this is kind of a circle game that i found no way out of.

i did not have so much difficulties before setting it up.. again it prob takes a pro 5 mins what i have struggled with the whole day

I have to work tomorrow, so prob not much opportunity to continue, but i might give you a phone call later on or tommorow, whatever suits you best bambi

[Mac1984]

And the never ending story continues...

Right:

Bambis Pump bolted on, timing belt fitted again, handcranked the engine a few times, timing pins still spot on,
trying to start, fuel comes out of the injector lines at the top, happy days, injectors connected, but : nothing

As soon as i tried to slacken the 4 bolts on the pump, it jumped back to the left with a loud click.. cant really drive it any further to the advanced position anyway, but now its even more the opposite way.

i still think the pump seems to pull an awful lot backwards, but not sure what i can do about it..

As fuel is coming, i am assuming the timing of the pump or some other setting of it is not right??


Other thing i can think of: maybe i have wrongly connected the injector lines to the pump, but it looks right to me, and they seem to only fit that way, given the shape they have.

Thanks for your input guys,maybe i am close to a solution, maybe not..

[Chug]

Well done for persevering Mac, many would have thrown in their towel by now!

I don't know the score with Bambi's pump but I assume it was just removed from a running engine and has not been rebuilt, or had the timing fiddled with?

At this stage without a dial guage to set the pump timing all that you can do is try it at maximum either way retartded and advanced within the slot on the pulley, and then depending on what happens (fires, doesn't fire ) maybe move the belt a tooth either way on the pulley.

I will look at my injector pipes and report back with which pipes go to which cylinder.

Looking from the front of van,
top right on pump goes to no 1 cyl
top left on pump goes to no3 cyl
bottom right on pump goes to no2 cyl
bottom left on pump goes to no4 cyl

order if looking from back of pump, pump rotates clockwise so firing order 1,2,4,3
top right no 3 cyl
top left no 1 cyl
bottom right no 4 cyl
bottom left no 2 cyl

[Mac1984]

Thanks chuggy,

I don't give up easily, and I love my smiley van, so hopefully it pays off sooner then later to keep going.
Like I mentioned before, I don't really have experience with Bosch pumps, so I can't say which way they should behave .

I dont think Bambi's pump has anything wrong with it, the previous pump didn't have so much back pressure, I don't know what level is normal.

During my last attempt yesterday the engine was spitting out white vapour, so I might be getting closer. Not sure now if that suggest too advanced or too much retarded pump.

I can get a dti ok, I still don't understand 100 percent how to do the precise timing on the pump, but there is some stuff on YouTube all right, if I find the time I check that out again.

Maybe the timing belt is out a tooth? I seem to struggle a lot as the pump gives back pressure all the time, and a few times it pulled back the can sprocket so the pin was stuck.

Maybe the pump was not timed right or some other problem with the engine, so that's why the previous owner set the minimum throttle screw so far up?

I am playing all these things through. Must be possible to break this curse .

Thanks chuggy for being with me on this still, your help is much appreciated.

[Jim Archer]

Easy answer with the HP lines is use Bosch pump ones - the injectors are the same type.

TD timing - pin up crank, cam, and pump.
Fit belt working anticlockwise, so engage belt on crank, then cam, then pump pulley with bolts loose enough to let it rotate (in middle of slots), then round tensioner.
Tension belt, pump pulley will probably move 'back' a bit. Use spanner on pump shaft nut to hold hub so timing pin is free fit and torque pulley bolts.
Remove pins, turn motor over, check timing, etc. Don't worry too much at this stage if the pump pin doesn't quite go in as you are about to move it anyway, just as long as it is close.
With crank and cam pinned up, loosen the pump pulley bolts and turn the pump shaft clockwise to the end of the pulley slots and tighten.

It should now fire up OK-ish once bled up, might be a bit too advanced so it kicks back against the starter. You can now fiddle the pump timing to find the 'sweet spot'.

If you have access to the DTI kit, you have 2 options; just time pump on the pulley to give the correct lift without the pin in place, or re-time the pulley hub to give the correct lift when pinned up.

Jim

[Mac1984]

Thank you very much Jim for your detailed response.

I have not done anything to the an yet, hopefully get some time on Sunday .

Out of my head id say I have pretty much done as you said, but I will follow
What you stated there step by step and see if I missed something there.

I also think I have the answer what went wrong with the previous pump.
It was running great, but the next day it would not start. Maybe it was letting air in over night at the pump seal,
But I made the mistake of removing all bits and eventually reinstalling a screw out of my box that was slightly longer and it must have caught the edge of the pump housing, as there is a small piece chipped off.
That resistance must have broken something inside the pump.
I will see if it is fixable, because until then it was running fine

So basically I have done some transit CSI , and surely won't do that mistake again

I let you all know how I am getting on with the project.

Thanks for all your help guys

[Mac1984]

Hi Guys,

thanks for all the Help regarding my Bosch Pump.

I did not manage to get the engine running with the second pump. The first Pump, that was running fine the first day, has been sent to a diesel specialist,
who told me that the hydraulic head has sheared of. Thanks to a spare part lying around, im able to get the pump fixed for a great price, should receive it next week
and will try to get that one running again.

so far so good, still not giving up

cheers and happy easter everybody

[Chug]

So we got to the bottom of that one in the end then eh Mac? as you say maybe caused by the bolt you fitted being too long and catching on the pump casing, I hope the refurbished pump does the trick, fingers crossed.

Cheers
Chug

[Mac1984]

Chuggy my man,

looks good so far. i was too busy with work until yesterday and today, so again full effort with the pump that came back from the diesel service.

it did not have so much back pressure at all compared to the other one, and only after a few cranking attempts fuel came up, and after tightening all up, the engine came to live...

starts very nicely too, i hope after a while sitting this will also b the case, but i assume if the reason before was air coming through a seal, this has been adressed.

They showed me the hydraulic head also, the plunger has sheared clean off..


i need to fiddle a bit still, idle speed is around 1500 revs at the moment

but so far it looks promising. why i was unable to get bambis pump running... i do not know. When i get time on my hand, i will take a closer look at it and maybe get it refurbed too in the near future as a backup.

thanks to all of you for your advises, it is much appreciated.

[bambi mk 1]

Give me a call tomorrow I lost your number .

[Mac1984]

Sure thing Bambi, I ring you later.

I'm pretty sure your pump is good, just whatever state of tuning it's in, I can't set it up right. However, for peace of mind I'd rather have a refurbished one installed anyway.

As I was pretty broke for the last weeks, it took a bit longer, but so far now it's running pretty decent .

The only bit left now is the pedal, I've read everywhere that would be a straight swap, but I had to do some playing to do for the cable to come through the bulkhead. Maybe I have an older type manual pedal, as it has 3 bolts rather then 2 like my epic one. But this is minor now compared to swapping a pump.

Thanks again to all of you being so helpful.

[Chug]

Hey Mac, great to hear you are up and running again.

Who did the IP work and how much did it end up costing, if you don't mind me asking?

[Mac1984]

Hi chuggy,

The overhaul of the pump was done by the company Portlaoise Diesel injection in Co. Laois.

Your man there is an old fox with a few decades in the business under his belt, luckily for me, he had an fitting hydraulic head lying there, and built the whole thing up for me for around 200 Euro.

Because I was tight for money at the month before, I had to give this operation a few weeks extra, but I think it's very reasonable, and I can totally recommend this company for their support and good customer service.

So hopefully now there will be troublefree motoring for a while:-)

I did a short drive yesterday, all satis, runs well, just the high idle I need to address at the weekend. And hopefully the fuel consumption won't be much higher then before

Thanks for all your advice and support.