Author Topic: Pump Assembly. Please Help! (Read 5481 times)

faulknern · « **on:** July 18, 2006, 12:43:25 pm »

Hi everyone,

I've been having some issues re-assembling my injection pump and I was hoping for some experienced help. The car is a 91 1.6 TD. I had the pump apart down to the camplate and rollers. Upon initial re-assembly the motor would start, but rev uncontrollably. I took everything apart again and noticed that the adjusting collar ( right term? ) wasn't engaged in the governor / throttle. So I assumed that would cause the problem and re-assembled only to have it not start at all now! So I dis-assembled again, thinking that I may have installed the camplate in the wrong position so maybe the plunger was trying to give fuel to the wrong injector ( possible? ). To my surprise, the plunger is snapped in two! So now I'm officially stumped and not sure what to do. I must have had a piece of dirt in there or something? Or could there be another problem? Would the camplate being out 180 degrees cause the engine to not start? Any ideas as to what I'm doing wrong? I'm just worried if I assemble it again with a different plunger I'm either going to break it again or it's still not going to start. Whew, sorry about all the typing. Any and all help and insights would be great. Thanks!

-Nick

QuickTD · « **Reply #1 on:** July 18, 2006, 05:15:49 pm »

The plunger likely broke when you installed the head/plunger the second time. If the bolts in the head are not tightened evenly the plunger will snap. The camplate and plunger are pinned together but the camplate can be installed 180º out of time and it will cause the engine to not start. The plunger drive pin on the camplate should line up with the driveshaft keyway.

A couple of tips for successful pump fiddling, it is very important that you keep track of all the parts and their exact locations, all those things that look like washers are usually shims, keep them together with thier respective springs or mating parts. Cleanliness is vitally important, the smallest speck of dirt will seize the head tight. Don't handle internal parts with dry hands, wet them with clean fuel or wear rubber gloves, the acid from your skin will etch the parts.

faulknern · « **Reply #2 on:** July 18, 2006, 06:55:50 pm »

Thanks for all of the suggestions Quicktd,

I was extremely careful about keeping the parts clean, but unevenly torquing down the head hadn't occured to me! I actually think I did get a little rushed the second time and had things a bit crooked so I bet that's what happened. Is there a way for me to tell if I have the camplate in the right position? Possibly using TDC or something? Anyway, thanks again for all of the tips! I'll give her another whirl and let you know how I make out.

-Nick

QuickTD · « **Reply #3 on:** July 18, 2006, 07:16:31 pm »

Quote

Is there a way for me to tell if I have the camplate in the right position? Possibly using TDC or something?

Yes, as I stated in my first post, the little plunger drive pin in the camplate should be lined up with the keyway on the pulley end of the drive shaft.

faulknern · « **Reply #4 on:** July 19, 2006, 11:20:42 pm »

Sorry about that, didn't fully catch that the first time. Thanks for the reminder.

fatmobile · « **Reply #5 on:** July 28, 2006, 12:15:01 am »

Spin the pump by hand after you get it put back together.

faulknern · « **Reply #6 on:** July 28, 2006, 07:14:59 pm »

Hey guys,

Thanks again for all the help. I was just browsing and came across a post that mentioned that keeping the rollers in their original position is important. Is this absolutely necessary? The reason I ask is my pump is still mounted in the car horizontally so when I took it apart the first time everything kind of went "boing" - for lack of a better word. There is no way I will be able to put the rollers back in their original positions. Should I stress about this, what potential consequences could this have? Thanks.

-Nick

QuickTD · « **Reply #7 on:** July 28, 2006, 07:48:53 pm »

How the heck to you plan on assembling the pump in the car? Do yourself a favour and remove 5 more bolts... There is no possible way you can do a proper and clean job with the pump mounted sideways on a filthy engine. The only parts that can be sucessfully serviced on the car are the LDA and the governor. Removal of the head requires pump removal, it's that simple.

The rollers should be kept together with their shafts and in the original orientation if possible. The parts are mixed up it probably won't do any immediate harm, but the rollers and shafts will wear more rapidly if mated with different parts.

745 turbogreasel · « **Reply #8 on:** July 28, 2006, 08:58:31 pm »

Sorry to threadjack, but are there any special tools I shold buy BEFORE disassembling a pump?

faulknern · « **Reply #9 on:** July 31, 2006, 09:08:04 pm »

Thanks again Quick TD,

I've been hesitant to remove the pump the rest of the way as I don't have the tools for adjusting the timing or taking of the timing belt. I just bought them off ebay so hopefully they arrive soon. In hindsight I wish I would have done this to begin with, but it's been a learning process. To bad I mixed up the rollers, but I guess there's not much I can do about it anymore. Anyway, I appreciate you keeping an eye on my thread and helping me along. Until the mail gets here I guess I'm stuck.

faulknern · « **Reply #10 on:** August 02, 2006, 02:27:33 pm »

Well, as you can see from this thread, I'm not an expert! But from my short experiences once the pump is out there aren't any special tools needed to disassemble it - at least as far as I have gone. However there is a special dial indicator to set the pump timing on reassembly as well as a wrench to release the timing belt tensioner and a pin to lock the pump's pulley in place. A kit I bought on ebay comes with the dial indicator, spanner wrench, lock pin and a camshaft lock plate. Hope that helps and you have better luck than I have!

-Nick

Author Topic: Pump Assembly. Please Help! (Read 5481 times)

745 turbogreasel