Strip and rebuild 2.8 IP

[Flying Torquewrench]

Interesting Rick as in Oz they fix it with a plate and an O-ring. Found the post with part numbers, unfortunately no photo’s. Post is copied below.

Here is the Part numbers for the Cover Plate and O-Ring to rectify the hot start issue with the GU 2.8td.

O-Ring - 16826V0700 (Nissan)

Cover Plate - 09621 80901AU (Nissan Australia Only)
Cover Plate - 096218-1030 (Denso Corperation)

Denso manufacture the plate for Nissan, So our Patrol brothers overseas should be able to go to any Diesel Centre that works with Denso to order the part. The o-ring is a worldwide part number so any nissan dealer can get that for you.

 

[solarman216]

Been there done that, it is a crap fix that holds the advance piston in a permanently advanced state, did not do anything for my motor, the best fix is new distributor head and matching plunger, they are paired and lapped together with such fine tolerance that at 2000 psi there is almost no leakage past the plunger, but sadly my pump is obsolete and every pump service company I have contacted said not available that is why I went Chinese, Rick

 

[Flying Torquewrench]

Fair enough Rick. At least you do a proper fix and not a bodge.

 

[solarman216]

Been wondering why instead of incorporating a groove in the plunger they did not just shorten the plunger it is the same difference, the reason is it would invalidate the stock "k" value of 3.2 to 3.4 mm at BDC (pump plunger) not crank, and this would of course create confusion, Rick

 

[solarman216]

great info rick,but those who designed it in the first place am surprised the brain fits in the head.so thats where the low pressure pump is,often wondered.

Sorry mate was not ignoring you just forgot, yes I agree the brains that developed this were very superior, it is taking me lots of time to even start to digest the complexities of this pump design, Rick

 

[solarman216]

Well after a full day of normal work and driving I can say it is so much better, powers has been restored and hot starting while not perfect is so so much better, all for 0.2 mm shim, I have a mat that has a mini grinding machine recons he can finish off my rough attempt, with my set up it would be all too easy to go too far in an instant, not something I am prepared to risk, Rick

 

[solarman216]

Having had the starting issues return I decided to take my new plunger to an engineering firm to complete the groove that I started, picked it up this afternoon and the groove looked good, was not till I got it home and looked with a glass that they have rendered it complete scrap, to remove the burs caused by the grinding they ran some (by there standards) some fine emery paper over the plunger, making it completely useless, I whish I had attempted to finish it myself but eyes being what they are I was lacking confidence, to say I am gutted is an understatement, I have a couple of ideas for tomorrow, but if they do not work I will be looking for a cheap run around till another new head arrives from China, Rick

 

[Flying Torquewrench]

That is such a shame. You hand it to somebody else with the assumption that they do a good job and then it comes back looking like this.
When do you expect the new head to arrive?

 

[solarman216]

Mid August, so if what I can come up with tomorrow fails then be buying a dirt cheap runabout for a month, I cannot believe someone would treat a precision part like this in such a manner, I am truly gutted, Rick

 

[solarman216]

Had a few scotches so now thinking at my best, decided I cannot be having with putting on and off the motor for testing each time I do a mod, so going to arrange a very rudimentary test bed, I have a few spare injector pipes and injectors laying around so will assemble 6 pipes and injectors and try running it with a drill while on load not sure how big a drill I need but will give it a go as well as using my optical rev counter to get around 100 revs which is approx. cranking speed if it works cold I will then heat it all up to simulate a hot engine, if my drill proves not powerful enough I can always stick it in the lathe, watch this space, as said before I will not be beaten, Rick

 

[solarman216]

While looking for a new head I found another for a Cummins, was very tempted but bottled out as it had a 12mm plunger, (sure Makeitfit will tell me off) but went for a 10mm one instead, and picture shows the all important groove, we will see but at $67 US delivered how could I say no? Rick

 

[Flying Torquewrench]

Personally I wouldn’t faff about with a drill. I would stick it straight in the lathe, at least you know that it can easily cope with it. Also for a compression test they recommend 200 revs so 100 revs might be a bit low.

 

[solarman216]

Personally I wouldn’t faff about with a drill. I would stick it straight in the lathe, at least you know that it can easily cope with it. Also for a compression test they recommend 200 revs so 100 revs might be a bit low.

200 is crank revs and approximate starting speed but this is IP and runs half engine speed, Rick

 

[Flying Torquewrench]

Not sure why I didn’t think of that myself. One look at the cambelt and it is clear that the fuel pump only does half the rpm. I blame the hot weather.

 

[solarman216]

Well just finished getting it all back together,, yesterday I rigged up a rudimentary test bench and with my original head only got dribbles from the injectors, so fitted the new head with the plunger that had abrasive taken to it and lo and behold all 6 were spitting nicely, I can only assume that the part of the plunger that was not touched was doing all the work, whatever now it is in the motor it starts when hot, bit low on power but I can live with that till the new head arrives, Rick

 

[Banshee]

Nice result Rick

Not surprised it all went to post the minute you entrust someone else with the responsibility of a job

Glad you have a solution until the new head arrives

 

[Banshee]

Any news on the new head Mr Solarman?

Bet you've been reaping the rewards these past few days??? :naughty

 

[solarman216]

Yes sun is good for me more hot water than we can use and fully charged batteries, the new head should be here around 10th August, but I am not so sure it will be any improvement on the first new one that was mullered but is running very well, my intension is to fit the new one when it arrives and take the other two to an expert I know to explain why my old one does not work and the mullered one does, I am clearly missing something but cannot see what it is, Rick

 

[solarman216]

New head turned up today, but no groove in the plunger also the plunger springs are recessed into the head which means I need longer springs, fortunately the 2.7 pump has spring recesses, so hope I can jiggle bits between the two, still leaves me with a groove to machine, but it is at least a 10mm plunger, Rick

 

[solarman216]

So bit the bullet today and cut the groove, was not going to trust the other lot to do the job, did not take long once I set it up, a bit heath Robinson but did the job, the threaded hole in top of angle grinder has a similar one on the bottom, into this is a made up bolt that fits the groove in the carriage, the strap and angle piece keeps the tail end happy