leaking injector pump

[hitch]

My 96 130 defender 300tdi fuel injector pump has started leaking so a rebuild is on the cards!
The question is , that I have a 98 dico 300tdi as a paddock bomb / ornament and was looking to swap the injector pumps if they are identical while I rebuild the defenders pump . Is this do-able ?

[Blknight.aus]

yep

[hitch]

Thanks Dave . Can you point me in the direction of a supplier of a rebuild kit by any chance ?

[hitch]

so if or when I get the injector pumps swapped over (a bad start to the job by rounding off a bolt head means I will be removing the timing cover and doing the belt replacement on the old disco engine as well !) what is the consensus re doing just the minimum seal replacement vs a complete strip down of the pump ? an acquaintance who is a mechanic suggests handing it to an expert and forking over the $1 - 2000 to have it done professionally.I have just rebuilt the engine so I am not a total beginner ( despite the rounded off bolt head !)

[Bazzle218]

In my opinion, given the time you may take stripping pump and repairing it , only to find it leaks straight away or soon after, worth the money of a rebuild. If your confident go for it plenty of how to on the internet. As for the stripped bolt, my mate whom is a Landy guru in Townsville only ever uses single hex sockets on his rovers. Have not broken or rounded a nut since following his advice whilst working on my 130.

[Blknight.aus]

just swap them if it was running and not leaking before so long as it hasnt dried up its usally fine to drop in...

for a few days at least.

[Lionelgee]

As for the stripped bolt, my mate whom is a Landy guru in Townsville only ever uses single hex sockets on his rovers. Have not broken or rounded a nut since following his advice whilst working on my 130.

Hello Bazzle,

About six months ago I started to use single hex sockets to initially crack free nuts and bolts on Land Rovers and other vehicles too. The result has been - like you and your mate's in Townsville suggestion - no broken or rounded nuts since then.

I just picked up a 3/8 inch drive set that ranges from 7 mm to 19 mm. I wanted to have some sockets smaller than 10 mm. If anyone knows of a set that goes below 7 mm in hex sockets could you please let me know?

From what I have found online so far, a lot of sets are sized between 10-32 mm. Only a scarce few single hex sets seem to go below 10 mm. Otherwise the alternative is to buy smaller diameter sockets individually at tool supply companies

Kind regards
Lionel

[hitch]

thanks for the sage advice guys.
the disco still gets driven around the farm occasionally so the pump swap should be ok for at least a week !
I wasn't thinking when starting to dismantle things and didn't expect the bolts to be held in by locktite that strongly as i only use the "tool release" form when i use it . so in future i need to be more suspicious / aware of traps set by previous "mechanics" and use single hex sockets ,heat, and an impact driver. any other suggestions welcome.
I was wondering if there was any info on what measurements / specifications / wear for the injector pump internals to look for ,as I am ok with pulling it apart and replacing o-rings,seals and the throttle bush / shaft and looking for broken springs etc which I don't expect to find ,as it still works ok despite losing diesel faster than it leaks oil etc!( actually it doesn't leak oil very much, if at all' despite being a landrover)
thanks in advance
cheers
Andrew

[Blknight.aus]

for a field rebuild of the pump dont worry too much about the numbers for tolerances youre looking more for wear and damage.

if its a lip you can feel with a nail it probably needs questioning

match mark everything before you disconnect it and do it on a nice new(ish) white sheet or large section of butchers paper

[hitch]

I am about to remove the disco donor pump but I can't see anything when I look up inside the bell housing . it is a 300tdi 1996 automatic ,so will i see / find a flywheel with a "locking groove"? I have the pump locked with the no 1 cylinder inlet valve just closed.

[AK83]

..... but I can't see anything when I look up inside the bell housing . it is a 300tdi 1996 automatic ,so will i see / find a flywheel with a "locking groove"? ....

You shouldn't be looking "up" you should be looking 'back' into the flywheel.

Auto tdi the locking groove is located forward of the flywheel.
Vertical cover face between sump and bellhousing. You should see a cover plate with two bolts.

[Blknight.aus]

a socket onto one of the torque convertor mounting bolt usually works.

[hitch]

transplanted the disco injector pump yesterday/ last night and after a 8 hour operation the defender roared back to life much to my relief!

mistakes / lessons learnt DO NOT take the flywheel locking pin out just because you are worried you might start up with it in because you might make an error in the sequence of bolting the injector pully on and try to take out the pump timing pin before it was bolted on ! maybe I need a hook on it to hang the keys under the vehicle! up and down like a yoyo getting the timing slot back !

thanks to LateAgain for his design for the flywheel locking pin.

the locking plate for the injector pump I made worked well and was copied from others I had seen on here the only difference was I drilled the 2 holes out to 9.5 mm which gave enough wriggle room to line up with the holes in the pulley without having to elongate them

now I just have a leak from the front spill rail banjo or plastic return pipe to deal with . ( and a squealing belt and a leaking oil filled wheel bearing and ....)

query re auto 300tdi is there any indicator equivalent to the fly wheel slot in a manual 300tdi that the injector pump timing / valve timing is correctly synchronized?

many thanks to Blknight.aus et al for your responses / advice

edit ; postoperative complication

leak from front banjo bolt due to damaging tubing with spanner tightening injector pipe nut

swapped tensioner with disco to stop belt squeal

checked bearing oil . level ok . minor leak ?

found diagram of auto flywheel locking . now I get the "look back not up " reference thanks AK 83