Gone and done it now

[GQtdauto]

Against all sensible advice I've removed everything in the way of lifting the top off the injector pump , all screws holding the top plate on are loose and ready to come out tomorrow.
Could not find or get the relevant info I needed so took a punt on the diss assembly and so far so good , although the timing mark on throttle shaft to plate was out for some reason .
The intake ports looked like exhaust ports with burnt carbon and crap stuck to the valves .
Turbo to inlet manifold was leaking as well .
Hopefully will be able to get some pics so you can see what not to do and that's the way I have done it .

[TPC]

Are you going to have a big face palm moment tomorrow?
I leave that stuff to people that know more than me, and that can be a lot of people cause I don't know much.

[AB]

Very ballsy effort pulling apart a pump old mate ;)


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[GQtdauto]

Yeah without the right info I might have bit off more than I can chew we will soon find out .
I'm pretty sure I will be alright though , as for facepalm moment that could be tomorrow.

[Turtle_au]

Good luck.
I had a Cabstar with a BD30 engine that had a leaking top cover on the injector pump. Luckily I had the nissan workshop manual so I read through it.
I will and have repaired nearly everything as I am a tight arse, but draw the line at auto boxes. After reading the manual I was quite happy to pay someone $700 to reseal the pump and $500 to remove and refit.

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[GQtdauto]

My last line of work was a Winding mechanic , hundreds of springs , latches , cams , and you name it all in one machine and so far it's no different , the only difference to my diagram and what I'm working on is there is an electronic what I'm asssuming is an idle on the governor / throttle shaft .

[GQtdauto]

Ok it took an hour and a half to remove the top plate and 30 seconds to replace the O rings then 2 hours to get the bloody thing back on , if I had to do it again I would knowing what I know now it's probably an hour job tops .
Not a job for anyone with a temper .
I've still got a couple of hours putting everything else back together and hopefully will be able to bleed and prime and start it late today , I have to keep stopping because of my back .

Some pics .
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[Tip12345]

when we do it we scribe the lever position on the shaft . its the thing that most people f up !
some have the cover bushed as it wears badly.

[GQtdauto]

I did scribe the shaft position because it didn't align to the marks , I also noted in the photo the position of that slot on top of the shaft so I had two references .
Where were you when I was asking about doing this ? The shaft has some wear on it as can be seen in the photo .
The large O ring was not installed correctly and had pinched and flattened it wasn't perished as many suspected , the shaft O ring was worn and suspect it was also leaking but the mechanics that had a clue and looked were convinced it was the large one and one even showed me using compressed air .
All said I would need a reco unit , leaking is now fixed and I have more power than before .

[GQtdauto]

Rechecked for leaks today and two my horror it's developed a very small leak somewhere else , there was one O ring missing from the kit and I'm betting it's the culprit but it's easy to get to from the outside .
Back is still playing up so I can't crawl around to find the exact spot , not leaking from where it was before and I've rubbed the top sides as much as I could get at and nothing there leaking so assuming it's at the rear of the pump somewhere .

[Turtle_au]

BTW where is the starter motor located. It was under the pump on my cabstar, and the leaking fuel eventually killed the brushes and commmutator six months later.

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[GQtdauto]

Not under it but not far away and yes it's had a shower of fuel over it for a couple of thousand Kay's , just another thing to look forward to and being an auto means trouble if your starter goes .

[jsawrey]

Thanks for the thread and the pics good work very informative

[GQtdauto]

Thanks for the thread and the pics good work very informative

What I did was fairly easy , what you're doing is major work mate , it did stop the leak by the way .