I soon found that the video's must have used an earlier version of my 1993 Defender 200tdi. The cast web markings used to align Top Dead Centre were different. The video shows a close to vertical casting web mark and a more steeply angled casting rib. Mine just had the steeply angled pointing to 6 o'clock rib.
Also, the bolts and bolt holes in the Paddock support tool and the clone that I bought had different positions to thread the bolts through.
The video also shows how hard it can be to remove the locking plate from the injector pump even with the whole engine out of the vehicle. According to the commentary, the locking plate can fall down into the timing belt case! I used an engineer's scribe and hooked the locking plate out with the 90 degree bend point. Hooking the locking plate out with the scribe worked really well.
The other thing which was different was the Crank Timing Lock Pin that is supposed to lock into a slot on the flywheel. Firstly, I used locking pin like the bloke used. I then tried using a spring-loaded version of the pin that came with my kit. Either way I could not find the slot the pin locks into. I turned the engine over multiple times with a ratchet bar. As a final attempt at locating the notch, I took the guts out of the pin tool and I used an engineer's scribe held firmly up against the wheel and kept turning the engine over with the ratchet bar. I figured the central hole in the tool where the pin slides up and down should identify where the slot on the flywheel should be. Nope - no go - no slot or notch found. Perhaps my Defender has an after-market flywheel? Or it could be the difference between late and early 200 TDIs?
Anyway, I used what I had available - the TDC mark and the pump timer pin. The video mentions how the TDC pulley turns twice so TDC against the 6 o'clock angled casting web - marked in "Tipex' could be either in the right place or out by 180 degrees. I rotated the engine around with the ratchet bar and on the second revolution - the pump pin fitted in perfectly.
The difference between the Paddock kit and my Australian sourced clone kit was that I had to use the longer bolts to push the injector pump out. The video shows the bloke using much shorter bolts to push the pump out. I tried the short bolts first and they were just that; too short - they did nothing.
So with photographs tracing where pipes, pins and other parts go and copious notes written down - the Bosch VE injector pump is out of the Defender!
I drained the injector pump out at different angles overnight then wrapped and boxed it up. Australia Post now has my pump and is hopefully directing it to a company that reconditions and refurbishes diesel injector pumps. It is an exchange service. Plus a "Core" deposit, which means they are sending me a rebuilt pump while my leaking pump is on its way to them. Once they receive my pump I get the deposit refunded.
So sometime in the next couple of weeks a 6.5 kilogram package should arrive and I will be able to fit a diesel injector pump that does not spew diesel out everywhere. I reckon Queensland Department of Transport and Main Roads inspectors might not have liked the look of diesel leaking out during an inspection.
I also have a new steering pump on its way too. During the wait I will be installing new rear indicator/brake/reverse light combo units. Then remove the old non-functioning door catches and fit ones that actually hold the doors closed. Trace why the horn does not work and things like the fuel gauge. You know the usual check-list.
TopicToaster
Reply With Quote
Bookmarks