Club 80-90 Forums

I am just about to collect and fit a bosch ve injection pump from a (jx 1.6td 1988) which is identical to my own, that since changing the distributor seal has really caused me some headaches, so am going to fit another including pipe work.

Anyhow i am sourcing any info on changing a pump. I understand tdc on cam, pump and flywheel/clutch housing. Is there anything else i need to concern about? I will re-time once fitted.

The main thing to be concerned about, in my experience, is securely locking the bits that move (cam, pump etc). There is a kit available, perhaps one of those Sealey things, that consists of a flat plate for the cam lock, and a big plug type thing that locks the injection pump through the hole in the sprocket to the housing behind. You don't absolutely need these, they're just handy - and not expensive: I think I paid about 12 quid. If you don't have the locking tools, then a 4" hinge will do for the cam, and a suitably-sized bolt will do for the pump.

These I4 diesels are not the fine Swiss watches of the automotive world, so as long as you have the timing roughly set, the engine will run. Personally, I always use a bit of advance on the pump because it seems more fuel-efficient - but to get the timing exact you would need a dial gauge indicator after fitting the replacement pump to get the specified lift ... which I think is just under a millimetre. Unlike a petrol motor with a distributor, you can't really time these engines while they're running. You just have to adjust in small increments and be patient.

Obviously you will need to establish TDC on No1 cyl before inserting locking tools. And when putting everything back together, make sure any slack in the timing belt is on the tensioner side of the belt rather than the side running from injection pump down to crank pulley: this way, the timing won't shift when you put the tension back in.

This is one of those jobs you have to do a couple of times before it's right.

Just back from a weeks great fishing north, over 200 fish on the fly I now have the extra engine, pump etc... and the pump has not been opened or adjusted since factory so hoping for straight exchange.
Thanks for the input dekhella. I have all those necessary items including timing dial. I believe 1mm sounds just about fine, but as you say a little by little should see it right. update as and when.

Okay well fitted the pump and it started but was puffing some blue smoke, so retested the timing and yet again got a different reading so reset it and again it started but with less blue haze and a better tickover, but not quite there so decided to retest the timing and yet again got a different reading though not so far off, so reset timing and somewhat better, but still not happy with haze when throttling. Been long day so will try again tomorrow and maybe do a road test to blow it though, such is life

'Blue haze' sounds like oil being burned. This (possibly) being the case, it could be that the valve stem seals and/or turbo seals need to get up to temp before they'll seal properly, especially if the engine hasn't been run in a while.

I did a final retest of the timing this morning, just a little out so corrected and it fired up first time, yet.......... still that light blue haze more so under throttle. I am started to think maybe it could be a dodgy injector and read somewhere of the screwdriver test on the injectors. You place the blade on the middle area of the injector and you listen to hear the nozzle injecting.
So up for anything i tried and yes you can hear the nozzle spouting inside. I tested all four and found a distinct difference on number 4. It was spouting but it was certainly louder and more of a popping sound compared to the others, could this be the cause? I dunno?

Seeing as I now have a spare engine, am going to change out that injector but I could not release it? What is the method and best way to release the injectors?

You need a deep 27mm socket to get the injector out. Are you sure it's the injector, though? Unburned fuel doesn't produce the 'blue haze' you've mentioned.

And don't forget - if you remove the injector, make sure you put a new flame trap on it. Available from Brickwerx and other places.

I had all injectors cleaned and tested, no problems there, new flame traps fitted. New diesel and oil filter, plus 4.5 liters mineral 15/40. Started but unfortunately still getting that blue haze, with some darker smoke when revving?

I think my choices are narrowing:
1. Pump timing still not right?
2. Turbo may be dicky?
3. Engine is on its last legs? (i hope not )
I think i must get motor pressure tested today, to confirm number 3. or not

Could not get a compression tester anywhere today, they only sold those for petrol engines or those with a rubber bung? you poke in the hole? Will try and source some online tomorrow.

What are the compressions ranges I need to look for across all cylinders? I have no idea?

Well after yesterdays frustration, i decided to start from scratch.
Rocker cover off, all turbo pipes off (some do not look that good see pic), cleaned them all.
TDC cam, pump and flywheel/clutch.
Retimed to 1.0mm
Replaced everything, but alas even though somewhat better, that blue haze is still dogging me




I really must get that compression test!!