Diesel FIP

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You're welcome to come and watch. Timing kit arrived today. Got all the bits apart from the compression tester kit.

Just need to work out how it all works! Might start with the dial gauge and how it fits into the adapter ...
 
OK, tomorrow's the big day, weather permitting. All tools have now arrived. My plan is:

1) Remove inlet manifold to get an idea what I'm looking at.
2) Practice setting timing of old pump in case I break anything and to get a feel for how it is done. Check car still runs! Question: can I get a socket and breaker bar on the end of the crankshaft to turn the engine or do I have to use the tool that came with the timing kit?
3) Remove glow plugs and do a compression test on all cylinders. If issues here then might reassemble and look for a scrapper engine.
4) Replace the FIP with a refurbed unit. IIRC the tensioner cap has some massive Allen key shape. How do I get the cover unscrewed without an Allen key that large?
5) Time up the new FIP.

Fingers crossed it'll all come out OK. Anything likely to trip a newbie up?

Cheers.
 
Grrrrrr said:
OK, tomorrow's the big day, weather permitting. All tools have now arrived. My plan is:

1) Remove inlet manifold to get an idea what I'm looking at.
2) Practice setting timing of old pump in case I break anything and to get a feel for how it is done. Check car still runs! Question: can I get a socket and breaker bar on the end of the crankshaft to turn the engine or do I have to use the tool that came with the timing kit?
3) Remove glow plugs and do a compression test on all cylinders. If issues here then might reassemble and look for a scrapper engine.
4) Replace the FIP with a refurbed unit. IIRC the tensioner cap has some massive Allen key shape. How do I get the cover unscrewed without an Allen key that large?
5) Time up the new FIP.

Fingers crossed it'll all come out OK. Anything likely to trip a newbie up?

Cheers.
Click to expand...
Wammers will know the size of the Allen key, look on the Bay for sump plug socket set.:)
 
Grrrrrr said:
That's a good call. Got to be pretty close to a tow-bar bolt, IIRC.

Just about to find out ...
Click to expand...

17 mm bolt head fits. As does the proper tool a 17 mm Allen key. The tool that came with the timing kit is for locking the crank to undo or torque up the crank nut. Breaker bar or ratchet on crank nut to turn engine always turn clockwise NEVER anti clockwise other than a jiggle to get locking pin in. :D:D
 
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Grrrrrr said:
OK. And I am assuming I can test by replacing a glow-plug rather than having to remove the injectors?

Would this kit do?

DIESEL ENGINE COMPRESSION TESTER KIT / DIRECT AND INDIRECT INJECTION ENGINES | eBay
Click to expand...


Arrived looking like it had been kicked around the van and hit with a sledgehammer.

Did 2 cylinders and on the third the pressure release valve jammed and now it is permanently reading 300+ psi. Buggered. Bit miffed but considering the Sealey kit is £230 I guess that's why.
 
wammers said:
17 mm bolt head fits. As does the proper tool a 17 mm Allen key. The tool that came with the timing kit is for locking the crank to undo or torque up the crank nut. Breaker bar or ratchet on crank nut to turn engine always turn clockwise NEVER anti clockwise other than a jiggle to get locking pin in. :D:D
Click to expand...

Haven't got that far. Got as far as testing the timing on the old pump before removal. The dial guage adapter I got (US PRO VW/Audi 3-In-1 Bosch VE Fuel Injection Pump Adapter Timing Tool B3178 | eBay) doesn't appear to be the right size. Nothing for the pin to screw into and 1 pin is too short and the other too long. Arse.
 
Grrrrrr said:
Haven't got that far. Got as far as testing the timing on the old pump before removal. The dial guage adapter I got (US PRO VW/Audi 3-In-1 Bosch VE Fuel Injection Pump Adapter Timing Tool B3178 | eBay) doesn't appear to be the right size. Nothing for the pin to screw into and 1 pin is too short and the other too long. Arse.
Click to expand...

Funny i have exactly the same adaptor and mines fits perfectly. The pins screw into the end of the dial gauge. You will have to remove the ball end screwed into the dial gauge to screw the pin into it. You can then either screw the two parts of the adaptor together and use the long pin or use one half of it and use the short pin. One of the screw adaptors supplied should adapt the adaptor to the thread in the pump. Scratch your head and try again. The dial gauge then goes into the adaptor and when set is locked in place by the turn screw on the side. I somehow think you are going to struggle with this pump change.
 
wammers said:
Funny i have exactly the same adaptor and mines fits perfectly. The pins screw into the end of the dial gauge. You will have to remove the ball end screwed into the dial gauge to screw the pin into it. You can then either screw the two parts of the adaptor together and use the long pin or use one half of it and use the short pin. One of the screw adaptors supplied should adapt the adaptor to the thread in the pump. Scratch your head and try again. The dial gauge then goes into the adaptor and when set is locked in place by the turn screw on the side. I somehow think you are going to struggle with this pump change.
Click to expand...

managed it with the adapter not screwed in all the way. Looked at the ball but it doesn't seem to come out on mine. May try again but have a bigger issue ...

Old pump out. No issues.

New pump in. Bit of a wiggle with that wiring loom at the bottom of the support bracket and the oil pressure switch by the filter housing. Put the nuts on the FIP. Remove sprocket tool. Tighten FIP nut. Went to tighten the nuts up to finger tight so I can move the pump to time it ... used a socket on an extension bar (no wrench) for the engine side one as it was fiddly and the whole bl**dy stud dropped out! Nut wasn't even tight. It must have been loose and me taking the old pump off jiggled it and the last few threads gave way. Odd as the pump came out without any problems.

Either way, major head scratching now. Does that stud go in all the way? Can I fix it with Quicksteel? Doesn't seem to be any bite to use locktite.

Guessing FIP might be stable with 2 bolts but does that stud go all the way through the casing? Will it leak oil?

So, slightly sunburnt and very frustrated. Thought we were on the home straight and then this swerve ball hits. Bugger.

Any ideas anyone?
 
The hole goes all the way through.

The PC refused to work when I came inside and needed a hard reboot.

For some reason the tool to crew onto the FIP sproket no longer fits on either so now I cannot go forwards or back.

I'm beginning to wonder if perhaps there is anything today that is going to go right.

I really don't want to take the whole front cover and timing case apart. Missus is working tomorrow so that means a brick on the drive for the next week.
 
Think you had better get someone who knows what they are doing on the job. People don't serve five year apprenticeships for nothing. If you have taken the sprocket holder out to soon and buggered about with the pump loose the tensioner may have pulled the chain and sent the sprocket out of position. You should have a tool to relieve tension on chain tensioner so you can get the holder back into the sprocket. But you will have to remove the cam cover.
 
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wammers said:
Think you had better get someone who knows what they are doing on the job. People don't serve five year apprenticeships for nothing. If you have taken the sprocket holder out to soon and buggered about with the pump loose the tensioner may have pulled the chain and sent the sprocket out of position. You should have a tool to relieve tension on chain tensioner so you can get the holder back into the sprocket. But you will have to remove the cam cover.
Click to expand...

Recovered, I think.

Tensioner was holding pump at funny angle so it couldn't get on properly. FIP back off.

Threads aren't completely gone. Locktite and tightened stud back in. Waiting for it to dry now.

Oddly enough I approached a few people but no-one seemed to want to do it. One guy even said "you couldn't afford it". Nice. Landy specialist too.

Think we can recover from here. Cup of tea time ...
 
Grrrrrr said:
Recovered, I think.

Tensioner was holding pump at funny angle so it couldn't get on properly. FIP back off.

Threads aren't completely gone. Locktite and tightened stud back in. Waiting for it to dry now.

Oddly enough I approached a few people but no-one seemed to want to do it. One guy even said "you couldn't afford it". Nice. Landy specialist too.

Think we can recover from here. Cup of tea time ...
Click to expand...

Sounds like whisky time, I'm on my third but what the hell. You revved up for your get away on Thursday Wammers. Four more sleeps for me.:D:D:D
 
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