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