So back to work early and into a very cold shed now I have the right type of diaphragm - well I hoped so.
It seemed obvious what I had to do - get the new diaphragm seated into the little notch inside the pump body - push and turn. Unfortunately every time I tried it didn’t seem to be in the right position. I decided to mark the top of the diaphragm with a couple of pencil marks - for zero and 90 degrees - to try and help me get it into place.
After a couple more frustrating failures I realised I had to keep the lever arm fixed so that I could push the inverter down into the hole and twist it. Twice it went in and I couldn’t turn it enough to clip under the rim of the fitting. Then of course it got stuck halfway in and then pinged it when I moved moving the lever up and down. This wasn’t gonna be as easy as I’d hoped.
I decided to experiment using the old diaphragm and see if I could get the technique. That just proved it was very difficult and then the old one got stuck again. Eventually after 20 minutes I realised it was irrevocably stuck so I was going to have to do something drastic to get it back out. I decided as it was broken anyway I would just have to cut the top off to give me access to the peg.
I put tape around the base of the pump to prevent any metal dust getting in to and grounded away gently with the Dremel. I managed to cut the top off the old one, but even that took 15 mins of very gentle work. Eventually I’d removed the top and could see the peg had jammed under the mechanism - with a little wiggle it was out.
I then used the stump of the old diaphragm as a guide and realised I’d been pushing it in far too far. I clean everything inside and out again and went back to fitting the new diaphragm. Now knowing how far to push it was then easy to align and let it sit a little proud of the pump body.
Next I cleaned the threads of the machine screws and reassembled the unit. Making sure I did so in the right orientation having almost put it on back to front. I also added a tad of grease to the newly cleaned threads for good measure. The diagram kept moving in the pump so I put a couple of strips of tape to hold it in place while I got the first screws in.
That done I went to remove the small tapes - well one of them. The second tape seemed to have disappeared. I looked at the floor and looked at my bench and I couldn’t see it anywhere. I thought then that it was going to interfere with the diaphragm so I looked more closely, only to find it hidden behind the bowl - so the pump came apart again. Third time lucky. I managed to align first one and then the second screw opposite and then proceeded to fit the rest quite successfully.
So all in all almost two hours to reassemble the pump body.
I then went back to the garage and re-fitted the pump to the block - that proved relative easy - I attached all the fuel lines, replaced the coil and even managing to do the nuts up myself. I then refilled the bowl using the priming leaver - that immediately felt different and far more positive. I felt for leaks but could find none so left it to settle for a while.
Later I returned to refit the interior - and job done. So did the car start ?
Stay tuned for tomorrow's exciting episode.
Ended the day with a SAAB run to Harkstead with tools for jobs, in the rain.