VWDiesel.net The IDI, TDI, and mTDI source.

Model Specific Questions and Info => All Other VW Diesels => Topic started by: epowell on February 02, 2016, 11:30:50 am

Title: VW T3 1.6TD JX - tuning up and maintaining
Post by: epowell on February 02, 2016, 11:30:50 am
I posted here a few months ago requesting advice on how to adjust the injection pump timing on a Vanagon 1.6 TD JX engine...    ...since then, between a couple of long trips away from my van, I managed to get a start on this work with a lot of help from the guys at The Samba, in particular Andrew Libby. The problem however, at The Samba is that few people over there have Diesels, so I have decided to document my work over here.

I am a complete newby to this kind of work, so if anyone can offer any comments or advice (even seemingly obvious stuff) I would very much appreciate it.

The initial GOALS:
- change timing belt (TB) / tensioner
- adjust valve lash
- change cam seal
- change waterpump
- adjust injection pump (IP) timing
- adjust TB tracking
- adjust aux. belts tracking
- flush, refill, bleed coolant system

The WORK:

this is my van "GEorge" :)

(http://images.thesamba.com/vw/gallery/pix/1407759.jpg)

this is my engine

(http://images.thesamba.com/vw/gallery/pix/1408537.jpg)

this is the wierd place for the air filter

(http://images.thesamba.com/vw/gallery/pix/1408538.jpg)

these are the anti-vibe clips I made (super-glued and marred the threads)

(http://images.thesamba.com/vw/gallery/pix/1408539.jpg)





Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: epowell on February 02, 2016, 12:02:05 pm
this is the TB before removal - notice how the belt is tracking to the outside.

(http://images.thesamba.com/vw/gallery/pix/1422851.jpg)

aux. belts before removal...  they are also not tracking well - I would like to get the pulleys aligned much better.

(http://images.thesamba.com/vw/gallery/pix/1422852.jpg)

removing crank pulley

(http://images.thesamba.com/vw/gallery/pix/1429843.jpg)

crank pulley off

(http://images.thesamba.com/vw/gallery/pix/1430044.jpg)

special helper making sure everything's ok :)

(http://images.thesamba.com/vw/gallery/pix/1430059.jpg)

alternator is out, now removing brackets

(http://images.thesamba.com/vw/gallery/pix/1430063.jpg)

waterpump exposed

(http://images.thesamba.com/vw/gallery/pix/1430073.jpg)

waterpump is out

(http://images.thesamba.com/vw/gallery/pix/1431670.jpg)

waterpump

(http://images.thesamba.com/vw/gallery/pix/1431782.jpg)

Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: vanbcguy on February 02, 2016, 02:24:40 pm
Looking good! Appears someone used a bunch of RTV on the pump for some reason.... Eewwwww.....

Sent from my XT1097 using Tapatalk

Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: epowell on February 04, 2016, 04:50:40 am
Looking good! Appears someone used a bunch of RTV on the pump for some reason.... Eewwwww.....

Sent from my XT1097 using Tapatalk

I now have the waterpump apart - and am still undecided if I will:
1) simply put this pump back together and back in the van
2) purchase a new pump and keep the old housing which seems fine
3) purchase a new pump with new housing

the reason I consider simply putting the old pump back in is because when I removed the bolts to separate the pump from housing, those notoriously seized bolts just came off like butter. And the pump inside looks very good and new...   ...and knowing how easy it is to change a waterpump, it might make sense for now just to keep this one in there.

But if I do that I need a new gasket - O-ring - and to figure out the right kind of sealant to use.

(http://images.thesamba.com/vw/gallery/pix/1459888.jpg)
(http://images.thesamba.com/vw/gallery/pix/1459887.jpg)
(http://images.thesamba.com/vw/gallery/pix/1459886.jpg)
(http://images.thesamba.com/vw/gallery/pix/1459885.jpg)
Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: the caveman on February 07, 2016, 11:19:02 am
Not sure whether you know or not, but the worse thing about the T3s is how to bleed the cooling system. Do lots of research before driving it after replacing the water pump etc. Libby has a good trick using some plumbing to make a filler pipe stack, works great.
Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: epowell on February 08, 2016, 04:50:31 am
Not sure whether you know or not, but the worse thing about the T3s is how to bleed the cooling system. Do lots of research before driving it after replacing the water pump etc. Libby has a good trick using some plumbing to make a filler pipe stack, works great.

Yes, most certainly I will use the "LIBBY BONG" method to bleed the coolant system!
Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: Toby on February 16, 2016, 02:48:41 am
You have bigger fish to fry. The corrosion on the water pump and visible in the other pics indicates that you have acidified coolant. That is caused by acid formed from combustion products in the cooling system. Nothing else will do that. Fix it now before you have more problems down the road.

If you still have the old coolant check is "coolant voltage" with a DVM and a piece of brass. Set the DVM on the lowest DC volt scale and hook one lead to something brass. Put both leads (including the one with the piece of brass) into the coolant. You get a "brass/acid" acid battery that way. The voltage read indicates how much acid is in the coolant.

.050 volts DC an you are golden.
.300 volts and you have trouble.
.450-.700 volts and you are toast.
Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: epowell on March 28, 2016, 02:38:08 pm
You have bigger fish to fry. The corrosion on the water pump and visible in the other pics indicates that you have acidified coolant. That is caused by acid formed from combustion products in the cooling system. Nothing else will do that. Fix it now before you have more problems down the road.

If you still have the old coolant check is "coolant voltage" with a DVM and a piece of brass. Set the DVM on the lowest DC volt scale and hook one lead to something brass. Put both leads (including the one with the piece of brass) into the coolant. You get a "brass/acid" acid battery that way. The voltage read indicates how much acid is in the coolant.

.050 volts DC an you are golden.
.300 volts and you have trouble.
.450-.700 volts and you are toast.

Thanks Toby...   I have had the coolant out for a long time already so not possible to check it. Yes you are right...  the PO did not have ANY anti-freeze in the coolant at all!  So it was corroding the engine (what an idiot!).

Anyhow I have not updated this thread for ages...  since my last post I have done a huge amount of work - mostly with the help of Andrew Libby and some other great guys over on the Samba.

Here are the highlights:

cam out, checking valve lash
(http://images.thesamba.com/vw/gallery/pix/1432394.jpg)

pulling IP sprocket
(http://images.thesamba.com/vw/gallery/pix/1463341.jpg)

removing IP
(http://images.thesamba.com/vw/gallery/pix/1464334.jpg)

removing glow plugs
(http://images.thesamba.com/vw/gallery/pix/1465543.jpg)

IM shaft sprocket off
(http://images.thesamba.com/vw/gallery/pix/1464547.jpg)

problems found
(http://images.thesamba.com/vw/gallery/pix/1468447.jpg)

oily rear seal
(http://images.thesamba.com/vw/gallery/pix/1468434.jpg)

crank sprocket off
(http://images.thesamba.com/vw/gallery/pix/1467027.jpg)

ugly mess
(http://images.thesamba.com/vw/gallery/pix/1467024.jpg)

working conditions
(http://images.thesamba.com/vw/gallery/pix/1467016.jpg)

troubles removing oil pan
(http://images.thesamba.com/vw/gallery/pix/1468899.jpg)

injectors out
(http://images.thesamba.com/vw/gallery/pix/1468878.jpg)

hacked tranny mount
(http://images.thesamba.com/vw/gallery/pix/1468572.jpg)

damaged muffler
(http://images.thesamba.com/vw/gallery/pix/1468464.jpg)

turbo welded to exhaust
(http://images.thesamba.com/vw/gallery/pix/1469376.jpg)

messy turbo
(http://images.thesamba.com/vw/gallery/pix/1469365.jpg)

bent oil return line out
(http://images.thesamba.com/vw/gallery/pix/1469255.jpg)

IM shaft out
(http://images.thesamba.com/vw/gallery/pix/1469220.jpg)

fried bearing
(http://images.thesamba.com/vw/gallery/pix/1469216.jpg)

crank plate off
(http://images.thesamba.com/vw/gallery/pix/1469199.jpg)

a look at my turbo inside
(http://images.thesamba.com/vw/gallery/pix/1469709.jpg)

oil inside turbo to intake hose
(http://images.thesamba.com/vw/gallery/pix/1469697.jpg)

dip stick stuck into turbo from above shows that oil is not pooling inside turbo.
(http://images.thesamba.com/vw/gallery/pix/1469649.jpg)

checking oil pump
(http://images.thesamba.com/vw/gallery/pix/1472653.jpg)

oil pan off
(http://images.thesamba.com/vw/gallery/pix/1472608.jpg)

making IM shaft front bearing pulling tool
(http://images.thesamba.com/vw/gallery/pix/1478545.jpg)

new oil rtn pipe comes...  too small ID
(http://images.thesamba.com/vw/gallery/pix/1477630.jpg)

...so I drilled it more wide
(http://images.thesamba.com/vw/gallery/pix/1477629.jpg)

pulling IM shaft bearing
(http://images.thesamba.com/vw/gallery/pix/1478844.jpg)

new bearing installed
(http://images.thesamba.com/vw/gallery/pix/1479177.jpg)

(http://images.thesamba.com/vw/gallery/pix/1479175.jpg)

im shaft plate ready to install
(http://images.thesamba.com/vw/gallery/pix/1480481.jpg)

crank plate ready to install
(http://images.thesamba.com/vw/gallery/pix/1481407.jpg)

new FEBI (in spec), ready to install
(http://images.thesamba.com/vw/gallery/pix/1481416.jpg)

crank plate installed
(http://images.thesamba.com/vw/gallery/pix/1481422.jpg)

im shaft, seal, and plate installed
(http://images.thesamba.com/vw/gallery/pix/1481429.jpg)

oil pump installed
(http://images.thesamba.com/vw/gallery/pix/1481431.jpg)

oil pan installed
(http://images.thesamba.com/vw/gallery/pix/1481432.jpg)

(http://images.thesamba.com/vw/gallery/pix/1481874.jpg)

(http://images.thesamba.com/vw/gallery/pix/1481876.jpg)

oil return line installed
(http://images.thesamba.com/vw/gallery/pix/1481881.jpg)

crank bolt installed (ouch!)
(http://images.thesamba.com/vw/gallery/pix/1481888.jpg)

crank and im sprocket
(http://images.thesamba.com/vw/gallery/pix/1482175.jpg)

installing new shims
(http://images.thesamba.com/vw/gallery/pix/1482183.jpg)

cam ready
(http://images.thesamba.com/vw/gallery/pix/1482181.jpg)

cap #1 ready
(http://images.thesamba.com/vw/gallery/pix/1482178.jpg)

cam in
(http://images.thesamba.com/vw/gallery/pix/1482177.jpg)

second hand turbo found, considering rebuilding and installing
(http://images.thesamba.com/vw/gallery/pix/1483003.jpg)
Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: billclark on June 03, 2016, 12:16:59 pm
Thanks for great documentation... gives newbys i can do it too attitude.
Title: Re: VW T3 1.6TD JX - tuning up and maintaining
Post by: epowell on July 26, 2016, 03:54:38 pm
Thanks for great documentation... gives newbys i can do it too attitude.

Thanks... glad you enjoyed it - I should update!!!  :)
Title: VW T3 1 6TD JX tuning up and maintaining
Post by: byronEsset on May 12, 2019, 02:46:31 pm
I have a white engine serial number vg 3439271 d2300 x222 and a deutz serial number f3l912 can i swap them in a truck do they make a trane that will bolt up any help would be helpful