Partially disassembled...
Injector pump on its way to Suva
Yup, head down on the engine. I’m getting a real lesson in diesel engine rebuilds here. Here’s a list of the stuff taken apart today.
-fuel lines. Not only the four hard lines but about six other soft ones to the fuel pump, return line, etc
-Four injectors, eight bolts and multiple other stuff to get these guys out
-Intake Manifold. Turns out while there are “only” three bolts that hold down the injection pump, one of them is inaccessible without removing the manifold. This also means dismantling the dipstick holder, throttle cable and air intake filter as well. Not part of the plan.
-Timing gear plate. Once I got to the three bolts that hold the injection pump on, I found that the pump shaft is pressed onto a timing gear that doesn’t come out. You can access it through an inspection plate and see it, but it won’t come out with the injection pump.
-injection Pump. Finally got access to this guy. As above, it wouldn’t just come out. It’s pressed onto the timing gear. I had to disassemble the timing gear box nut and then with hammer and punch, bang the shaft out.
OK, I won’t mention that I had to learn how to identify where “Top Dead Center” is on cylinder #1, because if you don’t somehow reassemble the thing with the same alignment when it comes back the engine will explode…or something probably much worse. All you have to do is get a mirror, slide it along the side of the engine to the hole in the bell housing and look for the little etched mark on the flywheel as you rotate the main shaft with your socket wrench. Huh?
OK, so the whole mess is now on its way to Suva. I have no clue where we go from here. I’m trying not to think about getting the thing put back together.
So…tomorrow, we’re taking a break since there’s nothing we can do now until the parts come back–hopefully in a couple weeks or sooner. In the mean time we’re going to paddle board and then spend the afternoon and evening with John and Lisa (at their Villa) before they have to fly back to NZ on Friday. I promise to get some pictures up in the next couple days. It’s just been nonstop the last few…
OK dude, looks like you are about to get you license as a diesel mechanic. Congratulations. I would bet there are some YouTube videos to help steer you through the re-build. And, of course, you took photos as you pulled things apart to also help you remember how they were put together, right? Being especially careful to note the relationship of pistons, valves, and timing gear.
Not to cause worry but I blew up two race car engines before I figured out I really did need a timing light to check it. Turned out my distributor was locked in full advance. Who knew? Not a problem you should have though.
I would guess there is a diesel engine dude in Fiji as well. He might just come in handy at some point.
Just trust your car hop up genes. You’ll be good. 🙂