injector pump leak2001 260 swb possibly BODGED fixed

[Panage]

done another 50 miles still OK bodge seems to work marktinkerman

so did you take the screw and plastic part off which i dared not to

Before i threw the old one out, curiosity got the better and i took it off. Theres nothing there just a metal plate thats un removable and the contacts disapear down a small hole in to some orange waxy stuff, the screw just holds on that bit of plastic and does'nt go anywhere else. Bit disapointed really i could'nt get any further without extreme destruction, it's pretty solid, suppose it needs to be with 1500psi involved

[winterheating]

done another 50 miles still OK bodge seems to work marktinkerman

so did you take the screw and plastic part off which i dared not to

Before i threw the old one out, curiosity got the better and i took it off. Theres nothing there just a metal plate thats un removable and the contacts disapear down a small hole in to some orange waxy stuff, the screw just holds on that bit of plastic and does'nt go anywhere else. Bit disapointed really i could'nt get any further without extreme destruction, it's pretty solid, suppose it needs to be with 1500psi involved

1500bar not psi, 1500psi is only 100bar

[Panage]

OH!

[winterheating]

but the metering solonoid meters fuel from low pressure side(pump flow from tank) to the high pressure chamber inside fuel pump, so actually wont have to work under such high pressure.

[sams]

I managed to blow a fuse which gives same symptoms you've got mark

[sams]

I've totaly bled the system so theres definatly diesel at the injectors im starting to think the pump may be shot
Has any one else sufferd starting issues after changing the solenoid if so what was the problem?

I managed to blow a fuse on my second attempt at bodging by shorting one of the wires in the silver cap to earth .... gives symptoms you describe marktinkerman

[sams]

took the silver cap of, removed screw in centre of plastic bit and plastic bit that covers wires where they exit silver cover then ground wires away where they contact contacts using dremel with small round burr ( tried unsoldering but decided they weren't soldered after melting plastic bit) removed plastic bit then thoroughly cleaned end of solenoid using dremel and various diamond bits finally used pointed diamond cone with small ball on end to chase round join between casing and solenoid insert (tried removing but thought it likely to damage casing). Coated end of solenoid with araldite except screw hole then replaced plastic bit and screw then squashed plastic bit hardish onto solenoid with vise until glue set made up new wires and soldered onto contacts ( couldn't find wires the same as original so used wire with same thickness core and thicker insulation )coated inside of silver cap with araldite especially around edge and where wires exit ( couldn't refit plastic cover over wires as insulation to thick) using vise to hold in place until epoxy set then glued patch cut out of bottom of paint tin onto end of silver cover.

thought of improvement to bodge...... should have soldered piece of pipe in hole on silver cap rather than blanking it of then if it still leaked could have connected it to return pipe to fuel tank marktinkerman

[Panage]

Ill give the fuses a check. Found a couple of other issues - i gave it another bleed after letting it stand for a while as a last attempt and i got a huge hiss out of an injector, sorted that and then a mate noticed there was a gargle coming from the feul line, turns out it was leaking air fixed that and then we noticed the battery is in not so good nick . Ill fit a new battery and see what becomes.
Fingers crossed

[Panage]

Finally got mine to run today turns out the solenoid needs to be screwed in a hell of a lot tighter than you think, gave it a few more turns and starts up with easystart and it runs with the accelerater pressed. For some reason it wont idle As soon as you let go of the pedal it stops. Any idears anyone?
Im suspecting the two snapped glow plugs in which i know one of them doesnt seem to have an end on it, so it blows. I plugged it up with a bolt which didnt make any difference, it seems i need to bite the bullet and have me head drilled
Any one else had to have this done and how much did it knock you?

[winterheating]

Finally got mine to run today turns out the solenoid needs to be screwed in a hell of a lot tighter than you think, gave it a few more turns and starts up with easystart and it runs with the accelerater pressed. For some reason it wont idle As soon as you let go of the pedal it stops. Any idears anyone?
Im suspecting the two snapped glow plugs in which i know one of them doesnt seem to have an end on it, so it blows. I plugged it up with a bolt which didnt make any difference, it seems i need to bite the bullet and have me head drilled
Any one else had to have this done and how much did it knock you?

why dont you stip the intake manifold off, and weld the hole back up in the broken plug, if your engine needs the glowplugs to start, (it shouldnt as its a direct injection engine), then it would miss on 2 starting from cold.

[Panage]

At last she runs, after all that it was a cheapo jubilee clip that had let go on the feul line. Stuck a new one on and she was back to starting on first click. just air getting in i guess
Bunged up the glow plugs with bolts, worked a treat.