Club 80-90 Forums

Righto , i've given my rather smoky Ebber a good old service
here goes

Firstly disconnect the power to the unit , then remove the plastic cover on top of it , no.4 allen key on mine , then remove the little 7mm nut on top of the glow plug and then the plug its self (17mm). then remove the exhaust, the air intake and the fuel line and then the 4 10mm nuts then take off the two end caps .. then remove the unit to a warmer place

[IMG]http://i201.photobucket.com/albums/aa12 ... age016.jpg[/img]

remove the units rubber seal , and then the 6 plastic rivets , push the middle in with a nail , carefully then split the plastic caseing

[IMG]http://i201.photobucket.com/albums/aa12 ... age017.jpg[/img]

remove the three sets of wiring plugs
[IMG]http://i201.photobucket.com/albums/aa12 ... age019.jpg[/img]

and the brains its self

[IMG]http://i201.photobucket.com/albums/aa12 ... age020.jpg[/img]

Then remove the 4 cross head screws the hold the fan housing to the combustion chamber

[IMG]http://i201.photobucket.com/albums/aa12 ... age018.jpg[/img]

that done the unit will now split in two

[IMG]http://i201.photobucket.com/albums/aa12 ... age021.jpg[/img]

The fan houseing , note the gasket , this needs replaceing

[IMG]http://i201.photobucket.com/albums/aa12 ... age022.jpg[/img]

the old gasket

[IMG]http://i201.photobucket.com/albums/aa12 ... age028.jpg[/img]
clean up the fan houseing and then fit the new gasket

[IMG]http://i201.photobucket.com/albums/aa12 ... age036.jpg[/img]

the excess gasket removed

[IMG]http://i201.photobucket.com/albums/aa12 ... age037.jpg[/img]

the combustion chamber and cover

[IMG]http://i201.photobucket.com/albums/aa12 ... age023.jpg[/img]

remove the chamber cover 2 cross head screws , the inside of the cover , note the carbon build up

[IMG]http://i201.photobucket.com/albums/aa12 ... age024.jpg[/img]

clean up the cover using wire brush and thinners

[IMG]http://i201.photobucket.com/albums/aa12 ... age029.jpg[/img]

remove the gasket and the seal from the combustion chamber

[IMG]http://i201.photobucket.com/albums/aa12 ... age025.jpg[/img]
[IMG]http://i201.photobucket.com/albums/aa12 ... age026.jpg[/img]
[IMG]http://i201.photobucket.com/albums/aa12 ... age027.jpg[/img]

then comes the fun part , cleaning the chamber , i used a gun cleaner and again thinner , again note the carbon build up

[IMG]http://i201.photobucket.com/albums/aa12 ... age031.jpg[/img]

the carbon hehehe

[IMG]http://i201.photobucket.com/albums/aa12 ... age030.jpg[/img]

Then check to make sure that the air intake hole is not blocked , this is in the chamber next to the fuel intake pipe

[IMG]http://i201.photobucket.com/albums/aa12 ... age032.jpg[/img]

i cleaned the chamber and left to soak for a few hours before cleaning again and then start on the rebuild

First replace the chambers gasket and seal

[IMG]http://i201.photobucket.com/albums/aa12 ... age034.jpg[/img]

then the chamber's cover ,

[IMG]http://i201.photobucket.com/albums/aa12 ... age035.jpg[/img]

then refit the fan houseing to the chamber taken care with the gasket

[IMG]http://i201.photobucket.com/albums/aa12 ... age038.jpg[/img]
then refit the brains and the wiring

[IMG]http://i201.photobucket.com/albums/aa12 ... age039.jpg[/img]

then the plastic caseings and the 6 plastic rivets , these just push in

[IMG]http://i201.photobucket.com/albums/aa12 ... age040.jpg[/img]

[IMG]http://i201.photobucket.com/albums/aa12 ... age041.jpg[/img]

then its back to the van , refit all the other parts and the fire it up , this may take a few starts and it will smoke for a while ... Job done , and all for 20 quid and a couple of hours
this should be done once a year so the man at ebber told me

good write up mark.must service mine...

Cheers Rob , i've kept it simple and used pictures cos i always think its easier to follow that way ,

just got myself a timer and reset tool like yours , will try to do a wee write up on that as well when i come to fit it ...

top man..........

and you got all that carbon out again?
frell!

yup , sorry for those who weren't at the teccy weekend , i took twice as much carbon out of the chamber then ran it for a few hours smokey

I think the fuel pump was over fueling and i was getting air in the line from the tank to the pump

mark.where did you get your gaskets from...

http://www.eberspacher.com/dealers.php? ... on=dealers

Sheffield Tachograph&Tail Lift Services
01709 839000
Unit 4, Thornhill Industrial Park, Hope Street, Rotherham, South Yorkshire. S60 1LH.

Brilliant write up Mark - its really not that difficult is it. Will have to do mine when i replace the thermal cutoff switch.

I need to source some handy tool to clean the chamber with - what sort of gun cleaner did you use?

The question is, has this stopped yours smoking and is it fully functional again?

Ringo

it was the sort they use to clean guns... it was one i was given to me by a member a couple of years ago.its a small brass brush.on a extendable handle...

what sort of gun cleaner did you use?

T'Onion wrote:The fan houseing , note the gasket , this needs replaceing

[IMG]http://i201.photobucket.com/albums/aa12 ... age022.jpg[/img]

Well I'm not very technically minded but I can certainly appreciate your choice of refreshment whilst carrying out the task.

well it is a dirty job

Ringo me old you were there when i did the cleaning first time around , like Rob says its a brass brush set , i would have thought any good army surplus would do them,as for stopping it smoking , i won't know that for a few more hours of running , fingers crossed

T'Onion wrote: well it is a dirty job

Ringo me old you were there when i did the cleaning first time around , like Rob says its a brass brush set , i would have thought any good army surplus would do them,as for stopping it smoking , i won't know that for a few more hours of running , fingers crossed

hey mark you forgot the bit about breakin all the little fastners cos you didn't know how to get em out

little fookers .. will come out .. i have learnt to use a panel pin on them

Excellent thread Mark.

Besides some bits from gun cleaning kits, i have found that old dental tools are very useful to get into those little nooks and crannies.

wiki'd

https://club8090.co.uk/wiki/Ca ... berspacher