1.6 TD JX - Inj.pump shaft bushing worn?

[epowell]

Hi Everyone...

I have been away for a couple of months and now back to my van and my engine with this somewhat drawn out project to replace the TB, waterpump, and do valve lash etc.. In the process I discovered that the TB has been tracking right on the outside edge of the IP SPROCKET, meaning there is a TB tracking issue there for sure. Also let me mention that to my knowledge this timing belt was installed way too tightly... I now have the TB, tensioner, alternator, waterpump, camshaft, and shims all out.

Yesterday I discovered, amazingly, that the Intermediary shaft sprocket bolt is TOTALLY 100% LOOSE! But sprocket itself is still on firmly (I recently purchased this van from a guy who, prior to selling it, had swapped back INTO it the old JX, and took his new AAZ for himself) - I think it is obvious that the re-installation mechanic simply forgot to torque down that bolt.

Back to the TB tracking issue on the IP SPROCKET...someone on Samba suggested I check the IP SPROCKET for wiggle/play and last night I found some...

Woke up fresh this morning to again test the amount of "play" in the IP SHAFT via the IP SPROCKET. In order to determine if there is excessive play in the shaft caused by TB tension, I first determined that TB over-tension would cause "play" between 130 oclock and 730 oclock - and the opposite of this would be 430 oclock and 1030 oclock. The amount of play @ 130/730 is significantly more than 430/1030.

- 130/730 gives a touch more than 1mm play and a slightly 'shakey - loose' feeling.
- 430/1030 gives a slight wiggle, perhaps 0.2mm - but still feels quite solid.

I am going to take this as a clear indication that the bushings are starting to go... yes the seal is still intact... and the van was driving now very nicely...

My guess is that the right course of action now would be to remove the IP entirely, and take it to a BOSCH SPECIALIST to have the bushings replaced.

However I will wait for some feedback before jumping into complete IP removal.

...thanks

[dave friday]

What do the guys on "The samba"say about your pump? the pump on my van has a bit of play and the belt was tracking in towards the pump,After moving the pump cradle {on Andrews advice} the belt is tracking in the middle of the pulley!
A re-conned pump is over £600!!

[epowell]

What do the guys on "The samba"say about your pump? the pump on my van has a bit of play and the belt was tracking in towards the pump,After moving the pump cradle {on Andrews advice} the belt is tracking in the middle of the pulley!
A re-conned pump is over £600!!

Re-conmed pumps are a bit cheaper then that here in Czech.

The dudes over at Samba mostly have Waterboxers so only a few can help with my TD JX... but those few are God sent!!

Mostly they are saying that yes I need the bushings replaced, but in fact there is no urgent hurry... the IP SHAFT seal is not yet leaking and the pump is working still. They are saying that the pump will need to be fully dismantled in order to change the bushings and this requires very special tools therefore not really something to be done DIY.

That is interesting that you IP shaft was loose and you belt was tracking on this INSIDE! Perhaps the difference with mine is that maybe your shaft is generally all around loose? The think with mine is that my shaft is a little bit loose in general, but I have quite dramatically more looseness at the angle that the belt pulls on the pump, which tells me that the cause of the loosness is an overly tight belt, and FOR SURE before I removed the belt I noticed that the belt was really TOO tight.

Is your IP SPROCKET loose in all directions? Mine is loose at 130 oclock - 730 oclock (that is the belt pull angle) ...but mine is not very loose at the opposite angle 430 oclock - 1030 oclock... Is your pump shaft still loose or did u get your pump overhauled? I guess your belt is back on now so there is no way you can check the angle of your looseness.

Did you take the pump off by yourself to adjust the pump brackets? If yes, how did you get the IP SPROCKET off? Did u use a sprocket puller or some other method?

Thanks
Ed

[dave friday]

Hi Ed,I undid the pump mounting bolts with the pump in place,to remove the pump sprocket I wedged the back of the sprocket (with tyre levers) and with the shaft nut loosened give the nut a tap with a hammer...
Kr.

[epowell]

Hi Ed,I undid the pump mounting bolts with the pump in place,to remove the pump sprocket I wedged the back of the sprocket (with tyre levers) and with the shaft nut loosened give the nut a tap with a hammer...
Kr.

Ahhh... I have been also trying this method - but the sprocket is not coming off. However I am hesitating to do this method too forcefully since it can damage things... I tried it anyway, gently - didn't work, and I don't think I want to go more rough with it so looks like I'm in for finding a sprocket puller - - - - - - it's amazing how just a small operation can set you back days and days without the right tools.

[dave friday]

Yeah' my daughter and I have to make tools..I seem to remember tapping the sprocket with a hammer(with a bit of wood inbetween!)
Some advice from my daughter ;"always buy the best tools"after all your not paying someone to fix your van!