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Discussion Starter · #1 ·
Ok I' ve been hunting round the topics & found a few commenting on Diesel leaking from the solenoid & running onto the bracket & starter. I paid a visit to my local Ford dealer & he quoted me £92 for a new solenoid. After looking at the pic in the haynes Man is it possible to just replace the o-ring or does it leak from somewhere else which means a new solenoid. It seems that getting parts for this car is nigh on impossible down here as the local Motor Factors aren't able to get the parts.

At the moment my plans are:-

1. Replace the 2 fuel pipes from the pipes below the intercooler that run to the metal pipes on top of the engine.
2. Replace the material braided hoses running from the injectors & any other braided hoses.
3. New fuel filter, as I dont know when it was last changed.
4. New injector heat protection washers.
5. Possible new glow plugs( Is it possible to remove these with an ordinary spanner or is it best to do them with a glowplug spanner they sell in Screwfix.)
6. Got a second hand Steering rack from a MK2 ( hope it is the same) just need to get some new Teflon Washers.
7. Since the fuel leak the car seems to be taking longer to start & seems to drain more power, so I'll probably whip the starter off & give it a clean.
8. Possible replace some of the pipes running from the preheater & filter. not sure as these are plastic & have clips which connect them to the various parts. Guess they could be cone if I used jubilee clips on the newe pipes.

Any help with pointing out any issues with the above list would be appreciated
 

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Discussion Starter · #2 ·
Well finally managed to get some of the jobs done..

Had to book the car into a garage for the steering rack.. Gonna cost upto £160 for him to swap the old one for a used one I got from a off the shelf breakers. Teflon washers cost me £6 for 2 lil washers :( .One garage I asked said it was too much hassle for them & turned the work down.

Got the new lenses for the lights. £45 from ford, oddly one cost £25 & the other was £19. :crazy:

Fixed the leak from the Fuel shut off solenoid & replaced the small hoses on the injectors. Some had small splits in & when I removed them they had no fuel in.

Can't beleive the change in the car after replacing the fuel filter. Still doesn't start properly, so i'm getting some new bushes from www.woodauto.com. Suspect that the deisel has got onto the bushes, Hopefully replacing them will sort it out. I've managed to remove the rear of the starter will it was on the car, gonna save some time & hassle on removing it completely from the car.

just the Injector heat washers, large fuel lines & an oil change to go. :D .. The end is nigh
 

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Discussion Starter · #3 ·
Finally managed to get a good day & time to replace the starter motor bushes.

Things came apart pretty easily, I managed to get a set of small long reach sockets from Halfords to remove the long rods from the starter & what a sight greeted me.

The bushes had been reduced to a gundge by the deisel.I guess I would only have had another 10 - 15 starts before it completely packed up.

So I removed the bush mount from the motor & cleaned it with carb cleaner. Cut the old bushes off & soldered the new ones on. Cleaned the gundge from the motor end & refitted the bush holder with a 19mm socket with card tapped round it to make it the same diameter as the motor end as it shows in haynes (minus the card). Now it starts like a dream.

So if your starter is playing up have a look at the bushes first. Its a lot easier than removing the whole starter from the car.

Hopes this helps someone as removing the motor looks alot harder than doing it in place.
 
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