Fuel-Stop Solenoid Valve

[Peterr]

Any tips on removing the Fuel-stop solenoid from the rear of the Bosch pump without removing the pump? The xxx..146 pump has a bracket that extends up making it difficult to impossible to turn a flat wrench. Appears that I will need to remove the pump just to change the solenoid. Is there a trick to this?

[dumper]

I bent a open end spanner and ground the head to clear the plate I never tried a crow foot spanner but it could also work

[Peterr]

Thanks, I was thinking of cutting the top of that plate too.

[Peterr]

So finally got around to make a special wrench, worked great for removing
though will meed grinding down for a thinner and less wide profile before I can use it to tighten up the solenoid.

[Peterr]

Sent from my iPhone using Tapatalk

[Peterr]

In order to remove it completely it will help bending the electrical connector tab all the way down. Or struggle getting a little wrench in there and not dropping the nut into a black hole!

[Peterr]

I slightly stretched the spring to give it a little more pushing power to seal off the fuel intake. Hopefully the electro magnet can still be able to pull it up.

[Altransit]

We don't see much of this modifying and adapting, on here these days.

It's good to see that the age of invention (and adaptation) is still with us

Thanks for posting back with your solution

[Peterr]

Thanks to so many on this forum who have helped me get moving again!

Now stuck with a madly revving engine on startup after switching out the Lucas pump with a …146 Bosch, no LDA. First thought it was a runaway engine caused by engine oil getting into the air intake and combusting from an old turbo. Couldn’t shut off the engine until I cracked open the injectors. Similar symptom, however I had the air intake from the turbo disconnected, so it can’t be that. Possibly the high revving was sucking fuel past a weak fuel solenoid. Hence the spring modification.

Fuel pours out the PRV on the Bosch so I’m suspecting a blown gasket inside the pump causing over feeding of fuel to the injectors. Can’t be blocked injectors because the engine worked fine with the Lucas, apart from the Lucas eventually failing from leaking fuel.

I put an emergency manual shutoff valve inline with the fuel intake on the pump in case it goes mad next attempt to start.

Posted this misadventure on other forum topics but yet to receive advice.

[dumper]

The stop solenoid not stopping the engine is a sign of the pump breaking up inside used to get it a lot on Bosch pumps at work my own mk3 did it very common when they started removing sulphur from diesal

[Peterr]

I took the pump off myself from a working engine, however it was in a dry storage garage for a couple of years until I mounted it last month.

[dumper]

You never know with used parts if they are any good it’s a lottery

[Peterr]

Yup, but this was from a friend’s engine that I knew was working. He blew the head gasket due to loosing the coolant. Can’t imagine that would cause problems with the pump. But it already had +300k on it so maybe it’s time was up. I have another …146 pump I can mount to see if that works, but it was second hand and I had no guarantee it would work. If all fails I’ll take both to the Bosch specialist for a rebuild estimate. Or I can purchase a new …146 with LDA I found for 1300€. Can’t find anything else.

[cherniy_chack]

The problem of the engine revving wildly after starting and the inability to shut off the engine by disabling the solenoid is most likely due to the injectors having a very low opening pressure, and the pump's cycle flow is set to the standard injector opening pressure of about 270 bar.
The solenoid doesn't completely shut off the fuel flow to the plunger assembly, and the engine may run with the solenoid disengaged. I've encountered this.
I recommend removing the injectors from the engine and checking their opening pressure.
It should be around 250-270 bar. This applies to those injectors that are called "pencil" in English-speaking communities, and "Ч-shaped" in Russian-speaking communities.
Thick injectors before '89 are called "pencil" in Russian-speaking communities, but I don't remember what they're called in your country.
They have a lower opening pressure, and replacing Lucas with Bosch injectors can cause problems.

[Peterr]

Thanks for explaining! I’ll have the injectors tested, or replaced but I have no idea which injectors are correct . I have some extra injectors. I’ll post photos here.