1.6L TD in a Dodge Caravan

[92EcoDiesel Jetta]

Is that a new delivery valve or did you clean up the old one?

[arb]

Is that a new delivery valve or did you clean up the old one?

I cleaned up the one I removed, inside and out. Lub'd it with WD-40 when I reassembled it. I'm not going to use that IP now, but the one I resealed and cleaned...

[92EcoDiesel Jetta]

Wow it cleaned up nicely! I am surprised how the rust cleaned up to expose the original plating! I woulda thought the plating rusted away leaving bare metal? Did you use a wire wheel on a motor?

[arb]

Wow it cleaned up nicely! I am surprised how the rust cleaned up to expose the original plating! I woulda thought the plating rusted away leaving bare metal? Did you use a wire wheel on a motor?

Nope, first I hit it with carb cleaner in a spray can, using a new tooth brush, then I removed this residue with TriChlor brake cleaner. Then I low pressure glass bead blasted it, the blew it off with dry shop air and then washed again with brake cleaner before opening it up. Yes, it surprised me too.

[rabbitman]

Anyone have a trick to remove the lower IP bolt (the 3 bolt flange to the mounting plate) without removing the alternator & A/C bracket

Well there's a hole in the pulley for putting a socket through , unless I'm mistaken of what your talking about.

[arb]

Anyone have a trick to remove the lower IP bolt (the 3 bolt flange to the mounting plate) without removing the alternator & A/C bracket

Well there's a hole in the pulley for putting a socket through , unless I'm mistaken of what your talking about.

And the bolt on the lower part of the IP flange is a captive nut ? WOW !!  Its been so many years since I've swapped an IP. I recall seeing the bolt now behind the pulley.

[theman53]

oops. I thought you meant the bracket part on the engine not on the gear side of the IP 

[arb]

OK, it mounted the rebuilt IP and got the "Duralast" belt on the engine... I could not get the 60% higher priced Goodyear Gatorback belt any time this weekend.... So, I also loosened the the IP mounting plate to move it down so this belt would track normal... I will move up the other end of the IP tomorrow when I have the rest of the IP mount on the engine again. There was much to clean up on the inside  of the timing belt covers as well as the pulleys. I also spent quite a bit of time cleaning the intermeadate shaft pulley, cam pulley, cam pulley, IP pulley, and crank pulley to be free of diesel and oil. The IP mounts on the plate were straight forward. I took other photos but for what ever reason they did not upload..

[arb]

Started to drive the Diesel to work this morning.. some part of the IP mount must have slipped as at high RPM just before shifting, the belt walked over to the cover and started making noise !! I was near my wife's work, so I parked it there and took her car. :-((

[Rabbit on Roids]

there are both ways, some had a bolt under the ip, some had a goofy shaped piece of steel with a stud sticking out of it. i like the stud on the piece of steel, because you can get at it from the holes in the sprocket.

[arb]

there are both ways, some had a bolt under the ip, some had a goofy shaped piece of steel with a stud sticking out of it. i like the stud on the piece of steel, because you can get at it from the holes in the sprocket.

Mine is the stud on the steel "C" shaped.

I think my current problem was the bolt holding the end of the IP to the engine block mount in the center of the block slipped allowing the IP to swing lower on the nozzle side. I had to lift that side a bit when I tightened that one bolt, so the belt would track centered. Wish there was something to attach to on the head or block to have a "screw jack" to have fine control over the alignment of the IP and therefore the belt tracking. This is the only IDI I've ever had an issue with belt tracking. When the IP was off, I tried to adjust down the IP mounting plate at the end of the block, but I could not budge the cap screw on the back corner of the engine due to my custom engine mount. I didn't want to break the bolt, so I focused on the other end of the pump. Worked great Sunday and this morning until I got one block from home and was revving the engine somewhat high.. Pop and it sounded like I had a belt driven blower under the hood :-(

[turbosuzi]

What is the update about sundays adventure?

[arb]

The root cause of the belt near failure was the nut on the IP - either I never torqued it, or I didn't tighten it at all !! OMG ! Can't believe it. I put some red loctite on it and torqued it. Not problem with tracking now. I need to replace the belt and the lower belt cover now... Also, the IP has no power and smokes a bit more than usual when the engine is cold. Cold starts take a few tries now, and my max speed in 5th is 67 on flat ground. I was able to easily hit 80 and had plenty of throttle travel with the old pump. I had the timing set on 0.040" exactly, so maybe someone turned down the fuel or some of the nozzles are fowled.

[arb]

Assuming there are no air bubbles entering the pump, smoke at cold start would likely be either retarded injection pump timing, incorrect cam timing or a glow plug/injector issue. WRT the lack of power, how's the smoke/EGTs at full pedal?  Similar to the last pump or less?

Andrew

There is no smoke at WRT after it is warmed up, the other pump had a little. I never adjusted the fueling on the first pump, but who knows what was done before as the collar was off the screw. I can also get 10 psi boost if I wind it out, the other pump was maxing at about 8 - 8.5 psi.

I have driven it 40 miles, so all the air should be gone (I'll look to be sure something is not tight) Do you think I should check the timing again before touching the fuel screw (again, no way to know if this second IP had had the fuel screw moved. The idle is probably at 600 - 700 when warm and not at all when cold.)

[Rabbit on Roids]

sounds retarded. i got more boost and higher EGTs when i was running retarded.