The Dutch stole all 5-speed diesels! (nsfw?) HJ60 and BJ40

[hj 60]

That soup is what came out of the old sedimenter, shuld have removed it the first day i got the car:

The 8 mm inside (14 mm outside) rubber hoses can be removed by hand and no tools needed, diesel starts leaking instantly.

 

[hj 60]

Replaced with chaep and worldwide used Delphi water sedimenter with 8 mm connection fittings (2 in bowl and 2 8mm so 4 brass fittings)

 

[hj 60]

Installation is really 5 minutes, very nice to use as a spare and check the state of the sedimenter because see what comes next:

The bowl was not filled further (so good air tight, did not use any sealant: self closing thread) and manual states to mount filled.
When I test in 4th gear it stalled a bit but pulled trough in 3th quickly, later removed some air at the pump with running engine.
After little driving glass was full pretty quick.

 

[hj 60]

 

[hj 60]

So I used the old clamp, not sure what to do next, the glass bowl is not very handy and now attached with one original mount #13
But it drives and no leaks.

The clamp from the sedimenter:
#10

 

[hj 60]

Now time to look at the old sedimenter, drained the fuel: not good

 

[hj 60]

WARNING
The following images might be considered disturbing to some viewers!

 

[hj 60]

I warned you

 

[hj 60]

So this seems result of bio diesel cleaning the tank and lines.
I clean the filter often (and open it up but it is clean, no black stuff at all)
And I open the water drain often (a bit of rust, some stuff but never the above black stuff)

 

[hj 60]

The floater has a magnet and when up will switch on (make a connection)
Very easy to open:

The floater has a magnet and when up (floating) will switch on (make a connection)

HJ60 water sedimenter 23930-58010 test warning light:

 

[hj 60]

found part number under layer of tectyl black stuff #

 

[hj 60]

HJ60 water sedimenter 23930-58010 inside:

 

[hj 60]

diesel In and outlet at the top:

 

[hj 60]

Maybe fix it?

 

[hj 60]

Time for a lot of testing:

 

[hj 60]

And then after some time after parking, so engine a minute off, my daughter mentions a leak

The hose popped off, there is no instant pressure at starting so I hope no head gasket but:
-the clamp is not adjustable so might be a bit tired after being full open a few times lately with pliers
-the new rad had smooth paint on the brass inlet, that came loose
-and I used vaseline to get it on and off easy

 

[hj 60]

So now I will buy some more coolant and yesterday drained and refilled the transfer and transmission:

 

[hj 60]

Pictures of the rear hatch lock, the FSM mentions nothing about taking the lock apart:
hj60 rear hatch lock parts only accessible when both covers are removed, so the small one and the one with the hand grip!

the two bolts that hold the lock togehter were wrong

 

[hj 60]

Wait, what does the FSM say? > nothing

Brass tabs to switch light on.

 

[hj 60]

Cleaned all with diesel and used new white grease, opens again from inside: