Thread: More Diesel drama's

Hmmmm.... Interesting set of symptoms.

When you get it going, how does it drive on the HWY? Has it lost some of the top end speed too? If so, the fueling mechanism in the pump may have siezed (a common problem on vehicles here in the UK). It's quite easy to fix though a little involved when it comes to describing on a forum!

I've described the process on here before so I'll do a search & see if I can find it.....

Wait one.....

....Back again.

I found the thread and here's what I said:

I'll try to explain....

Under the 4 screws is the mechanism that will adjust the amount of fuel delivered based upon the turbo pressure. If you remove this cover, there is a rubber diaphram (which the pressure acts against) and bolted to the underside of this is a cone.

There is a rod inside the pump that rests on this cone and as the cone moves up and down, so the rod moves in and out. This rod then disappears down inside the pump to adjust the fuel.

It is quite common (especially if used in or around water) for the rod and/or the cone to seize.

The remedy (performed at your own risk!):

1 - Pop the 4 screws off.
2 - Mark the location/orientation of the diaphram vs pump housing. Peel up & see if it's free moving. If not, that's problem 1! If it's stuck, apply liberal amounts of WD40. Next, we need to get access to the "Rod".
3 - Mark & remove the throttle linkage.
4 - Behind this you should find a 5mm allen key bolt. Remove this and you should now have access to the other side of the rod.

Use the 5mm allen key & poke it into the hole! If everything is working properly, you should be able to feel the allen key move out as you lift the diaphram/cone. Ultimately, you should be able to just pop the cone straight out.

If not, keep attacking it with WD40 until it frees up with you moving the cone up and down while using the allen key to keep pushing the rod back in. Eventually, the cone should pop out.

Once out, grease up the cone & re-assemble.

Notes on assembly:
1 - Before you put the cone back in, make sure the rod is pushed back into place otherwise it will prevent the cone from being inserted. Just use the 5mm allen key to push it back in (you can see it poking out if you shine a torch down).
2 - If you forget to mark the diaphram location, you should be able to align from the grove that has been worn in the cone.
3 - When you fire the engine up for the first time, if the idle speed is wrong, you've put the throttle linkage back in the wrong position. Remove and put back on the next spline around.
4 - When you go on a road test, it will be sluggish for the first 30 seconds while it clears everything out but it should then jump into life.

HTH

Mark.

You can read the thread here: