p38 1997 Diesel fuel stop solenoid

[Bagshot]

Hi,
I am looking to change my fuel stop solenoid today as the existing one is leaking out through the top electrical connector. Has anyone done this and do I have to look out for any nasty surprises when I start. I have already stripped the components down once to access it previously to check the fault, but I will be looking to swap this tonight.
Cheers

 

[Grrrrrr]

@wammers area of expertise. Guessing there's a spring that is likely to boing over your shoulder at knots.

 

[Bagshot]

Joy..!!

 

[Grrrrrr]

It might be the guru's on holiday ... or maybe just having a bed wash. In case he doesn't respond this might help?

...

Hold on. Where's the file?! I uploaded it. Hmmm. Try again ... er. Strange. Says any PDF under 29MB is fine which is what it is. Bugger. Try zipped ... no. Arse. Oh well, guess you'll never know!

 

[Bagshot]

How hard can it be ...and what could possibly go wrong anyways.

 

[Grrrrrr]

How hard can it be ...and what could possibly go wrong anyways.

Well, the 2 things that spring to mind are bricking the FIP or watching diesel spray all over the engine bay followed by a whoooomffff! Still, got to live a little, haven't you? What's a world without risk like?

 

[Bagshot]

Who dares wins Rodney..

 

[tomcat59alan]

He's not away till the weekend dipping his rod fishing that is,.you need Bosch 032-201 028 12v (084) Thats the numbers I had when I looked for a replacement V expensive but at the time I looked they were £38.55. I should have bought a load of them.Nothing to worry about spring wise.

 

[Bagshot]

Thanks for all the replies here. I've got the part ready, Bosch genuine solenoid.( why is such a small thing sooo expensive..?)But fell at the first hurdle this time.. Got everything off down to the solenoid, but the B****** isn't coming out. Fixed solid. 24 mm spanner slightly loose and 23 mm too tight, started rounding off the faces of the nut so put everything back on and need to think about this some more..
Suggestions welcome before I really bugger something up.

 

[Mark Piercy]

try a 24mm socket with six sides and not twelve if you have one.. Or tap tap with a small hammer and chisel to shock it loose....

 

[Bagshot]

try a 24mm socket with six sides and not twelve if you have one.. Or tap tap with a small hammer and chisel to shock it loose....

 

[Wazzajnr]

What imperial size comes between 23 & 24mm? Might be worth getting an imperial that is between the two and tapping it on.
I remember doing one on a disco 1 years ago and it was a right bitch to get out. Trouble is, you can't really heat it!
Might be worth trying on a hot engine, might come out easier then.

 

[tomcat59alan]

Thanks for all the replies here. I've got the part ready, Bosch genuine solenoid.( why is such a small thing sooo expensive..?)But fell at the first hurdle this time.. Got everything off down to the solenoid, but the B****** isn't coming out. Fixed solid. 24 mm spanner slightly loose and 23 mm too tight, started rounding off the faces of the nut so put everything back on and need to think about this some more..
Suggestions welcome before I really bugger something up.

Yup thats why I needed to replace mine I damaged the top so it weeped diesel.j I cannot remember the size off the top of my head

 

[Bagshot]

Hi,
Can't get a socket over it, as its too close up to the front of the FIP. Also tried a ring spanner but that won't go over it either. Rather not start hitting the pump with a chisel, but appreciate the advice...or would the pump take the knocking..?

 

[Wazzajnr]

Hi,
Can't get a socket over it, as its too close up to the front of the FIP. Also tried a ring spanner but that won't go over it either. Rather not start hitting the pump with a chisel, but appreciate the advice...or would the pump take the knocking..?

Thinking about it, on the disco I did, I had some ancient spanners that were about twice as thick as the ones you get these days and I ground one of those out until it was a snug fit then tapped it on.
Was a pig to get any leverage on it but once it cracked it spun out by hand.

 

[Bagshot]

Cheers for this. Encouraged to have another go tomorrow. Got some old metric spanners that I can butcher up.
Watch this space..

 

[tomcat59alan]

Imperial or whitworth I think but limited space to get a turn on the spanner, there is probably a special tool for the job,Wammers will know.

 

[tomcat59alan]

I bought a full set of crow's foot spanners a while ago,I wonder if one of those would do the job. I'll try tomorrow when I've finished down the farm

 

[Bagshot]

Thinking might sacrifice a ring spanner, grind one side away and leave 3/4 of the ring.
Might be worth a go.
Could right though, I bet there is a special tool out there.

 

[Wazzajnr]

Thinking might sacrifice a ring spanner, grind one side away and leave 3/4 of the ring.
Might be worth a go.
Could right though, I bet there is a special tool out there.

I doubt it will be strong enough once you cut it. Better with an open ender