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Author Topic: 1.6 TD JX - Inj.pump shaft bushing worn?  (Read 4329 times)

February 04, 2016, 04:40:46 am

epowell

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1.6 TD JX - Inj.pump shaft bushing worn?
« on: February 04, 2016, 04:40:46 am »
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



Reply #1February 04, 2016, 01:13:29 pm

vanbcguy

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Re: 1.6 TD JX - Inj.pump shaft bushing worn?
« Reply #1 on: February 04, 2016, 01:13:29 pm »
It'd be a lot safer to do it now while you have everything apart - the pump bushing is a PITA to deal with since it needs a complete pump disassembly.  While it's not leaking now, it almost certainly will down the road...
Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #2February 04, 2016, 05:58:14 pm

epowell

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Re: 1.6 TD JX - Inj.pump shaft bushing worn?
« Reply #2 on: February 04, 2016, 05:58:14 pm »
...yeah I've pretty much fully decided to pull the pump and get it completely over-hauled...  at least thereafter I have rest knowing  that the most complicated part of my engine is freshly serviced :)

And furthermore, as long as I own this van I will make sure it never has an overly tight TB, therefore this problem ought never occur again prematurely.

It gives me a nice feeling to spot a problem before it rears it's head...  sure it will cost me a couple hundred bucks - mechanics are very affordable here in Eastern Europe...  but I've been well counting with this type of expense.

Now comes the fun part - trying to get the IP SPROCKET off...  I don't have even a sprocket puller let alone the special this job supposedly requires.  I was told about a technique for removing this sprocket without a puller - but seems it can be a bit rough... so much be gentle...  I'll give it a go tomorrow and hope to report success... 

I guess a lot of you guys here actually service your own injection pumps. One day I would like to try my hand at this too - but I am told it require a real learning curve, and some highly specialized equipment. Anyhow I will keep my eyes open for an old worn abandoned pump that I may take apart and learn on.
« Last Edit: February 04, 2016, 06:03:19 pm by epowell »

Reply #3February 04, 2016, 10:44:48 pm

vanbcguy

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Re: 1.6 TD JX - Inj.pump shaft bushing worn?
« Reply #3 on: February 04, 2016, 10:44:48 pm »
Getting the sprocket off can be a challenge.  I had to use a puller on the last one I did.  Some folks have used pry bars and things - that can work too though it can also warp the sprocket.

I think quite a few people replace seals and things - there's a fair bit of stuff you can do to the pump without having to get too far in to it.  However the input shaft bushing needs the pump to be completely stripped bare - if you have everything out of it then you might as well replace all the bits that are worn.  At that point you're in for a full rebuild, there's parts that need to be calibrated...
Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #4February 05, 2016, 09:41:54 am

epowell

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Re: 1.6 TD JX - Inj.pump shaft bushing worn?
« Reply #4 on: February 05, 2016, 09:41:54 am »
Getting the sprocket off can be a challenge.  I had to use a puller on the last one I did.  Some folks have used pry bars and things - that can work too though it can also warp the sprocket.

I think quite a few people replace seals and things - there's a fair bit of stuff you can do to the pump without having to get too far in to it.  However the input shaft bushing needs the pump to be completely stripped bare - if you have everything out of it then you might as well replace all the bits that are worn.  At that point you're in for a full rebuild, there's parts that need to be calibrated...

I found a local guess, highly recommended, who can do the IP rebuild for less than $200...   so I will take it to him.

Regarding removing the IP SPROCKET...  I just tried, and failed to remove it via the screw driver method without the sprocket puller...    Seems I need to go get a sprocket puller - I think I heard that a generic sprocket puller will not work on a JX IP sprocket?

Reply #5February 05, 2016, 10:14:06 am

vanbcguy

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Re: 1.6 TD JX - Inj.pump shaft bushing worn?
« Reply #5 on: February 05, 2016, 10:14:06 am »
I used a generic puller on mine, it didn't fit well and it did leave marks on the sprocket. I hooked in to the inside of the holes in the sprocket. It worked though.

Sent from my XT1097 using Tapatalk

Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #6February 05, 2016, 06:23:45 pm

epowell

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Re: 1.6 TD JX - Inj.pump shaft bushing worn?
« Reply #6 on: February 05, 2016, 06:23:45 pm »
I used a generic puller on mine, it didn't fit well and it did leave marks on the sprocket. I hooked in to the inside of the holes in the sprocket. It worked though.

Sent from my XT1097 using Tapatalk

OK...  good to know - - -  I well research a bit more and also have a look at what is available around here. . . . . . . I am also now toying with the idea of learning to weld > it seems more and more I need this skill to fabricate custom tools and bits for my van. . . .    geez I'm on a steep learning curve :D

Reply #7February 07, 2016, 10:03:03 pm

fatmobile

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Re: 1.6 TD JX - Inj.pump shaft bushing worn?
« Reply #7 on: February 07, 2016, 10:03:03 pm »
You found someone who will pull it apart, install new bushing and ream them, then reseal the pump for $200 including parts?
 That's pretty good. That's what I charge but can't benchtest it afterwards.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #8February 08, 2016, 04:52:29 am

epowell

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Re: 1.6 TD JX - Inj.pump shaft bushing worn?
« Reply #8 on: February 08, 2016, 04:52:29 am »
You found someone who will pull it apart, install new bushing and ream them, then reseal the pump for $200 including parts?
 That's pretty good. That's what I charge but can't benchtest it afterwards.

Yes absolutely, but I am in the Czech Republic where auto repairs are 2 or 3 times cheaper than in the US.

 

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