Dismantling bosch - help!

[Poodle]

As mentioned in my zx thread earlier, i'm trying to take the head off the pump to replace the seal. I've hit problems already and not really sure where to go with it. Any chance somebody could list what i have to do in order to remove the head of the pump..?

So far the lda pin is out and the head is unbolted, plus various other bits have been undone/disconnected to make it all more accessible. I realised i was stuck and went to put it back together, but think i've dislodged something as the head doesn't want to sit back down on the body of the pump nicely, and i don't want to force it.

99% sure i haven't disconnected anything i shouldn't, yet! Will go and take a picture in just a sec. Any and all input welcome, even if it comes attached to desultory (and probably deserved) comments lol.

[Dan!]

Sounds like the govenor cradle is sitting on the manual shut off arm. Lift the pump head up just like 1mm, then rotate the throttle armanti clockwise like 20 degrees, then it should drop down.

I might be getting confused, it might be clockwise, but I think anti-clockwise it right And deffinately dont force it, because you will break something

[Poodle]

Gotcha, can see it now cheers dan. Any idea what's stopping me from getting the top of the pump off?

[Dan!]

That will be the gov assembly still being in the leverset. I you lift up the right hand side of the pump (as you look at it if its fitted to an engine) and shine a torch in there you will see where it is sitting in the leverset. You usually have to til the top of the pump back a bit, then wiggle the gov assembly out of the leverset with a screwdriver, or your fingers if you have girly hands

[Mattcheese31]

Gotcha, can see it now cheers dan. Any idea what's stopping me from getting the top of the pump off?

you need to tap on the throttle shaft as you lift the head of the pump as it is wedged in the top of the pump by it's rubber seal . .

[Dan!]

Yeah, or you can do it the way matt says, although I always get scared doing that because sometimes its fairly well stuck in the throttle shaft, and tapping it too hard risk's it getting knocked out the bottom and cracking

[Mattcheese31]

Yeah, or you can do it the way matt says, although I always get scared doing that because sometimes its fairly well stuck in the throttle shaft, and tapping it too hard risk's it getting knocked out the bottom and cracking

true . . . .

[mark_airey]

You mean the lid and not the head right..........that or you have confused the shite out of me, the throttle arm needs taking off (10mm nut on the top of it) but make sure you mark the angle of the slot in the top of the shaft onto the arm (score it with a screw driver or something) or putting it back together will be a nightmare! then as matt says just tap it through the lid as you lift it off (never had a problem doing it like this myself), its also easier if you fully unscrew the max fuel screw to take the tension off the lever

there will be the small cold start spring at the back of the pump that will need unhooking as well once you clear everything else

[Poodle]

Got it! She runs, although the idle's a bit random. Big thanks to Dan!, also to Matt and Mark. Will update properly later to explain, going to take her for a run (definitely didn't fiddle with it while i was in there.... )

[Dan!]

Have you done a cheeky gov mod mr Poodle? :naughty:

[Dan!]

Also, the idle might just be because theres still a bit of air in the system/fuel pump. If that is the case it will sort itself out after a quick run up the road. Aslong as you put the fiddly twatting spring back in and didnt shim the idle spring on the gov cradle then I can see what else would have changed it

[Poodle]

Think the throttle arm might be a notch out. Mark gave that particular piece of advice about half an hour too late lol. Feels rather stronger on boost now, no gov mod yet though, especially since ive got my suspicions the head's not in the best shape.

Its still letting air in somewhere too, not so sure its all the pump. Its also still cutting at random... might fiddle with the stop lever and see if that improves it.

[mark_airey]

Think the throttle arm might be a notch out. Mark gave that particular piece of advice about half an hour too late lol. Feels rather stronger on boost now, no gov mod yet though, especially since ive got my suspicions the head's not in the best shape.

Its still letting air in somewhere too, not so sure its all the pump. Its also still cutting at random... might fiddle with the stop lever and see if that improves it.

gutted, yeah there is a reason I said that which you have now discovered as for the cutting at random, connect the stop solenoid directly to the battery (this will rule out the wiring if it still does it) or just remove the plunger from inside the stop solenoid (you will have to stall it to switch the car off if you do this but if it still cuts after that then its not the stop solenoid) air will most likely be the filter housing leaking, if you fit a bit of clear tube between the filter housing and the pump then you will be able to see if there is air getting in before the pump

[Poodle]

Hahha yeah, revved it's bollocks off the first time i started it, soon fixed that. How the hell are you meant to get the throttle arm back on by yourself though, don't understand how you can hold the spring in place, twist it through nearly 180 degrees and bring the arm itself into position at the same time?!

That'll keep me busy for a bit, ta. Will see what happens

[mark_airey]

I normally drop everything into place, locate the bottom of the spring when you put it on and then use a pair of pliers to pull the spring round and put it under tension then slip top plastic cap on followed by the arm and then hook the spring on, its good fun

[Ruan]

Long nose pliers, hold the throttle arm down, and yank round and clip on..

[mark_airey]

Long nose pliers, hold the throttle arm down, and yank round and clip on..

Is that not what I just said just using less words

[Ruan]

I just tend not to read your posts mark xxx