2.5 Na desiel Injection pump removal and refit - Defender Source
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  #1  
Old December 3rd, 2013, 02:02 PM
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Alistair Davidson
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2.5 Na desiel Injection pump removal and refit

Have an 86 ex mod 90 with a leaking injection pump. Getting ready to pull pump out and send in to an injector specialist to have resealed.
I have ordered the timing kit and tool to help pull the pump. I have a couple questions before i start though if you guys can provide any info...
-Some of the research ive done online indicates that it is necessary to get all the timing marks lined up before taking the pump out. Is this necessary or is this something you can do once youre ready to install the resealed pump?
-With the appropriate tool I am planning on not needing to take the whole timing belt case+accessories off and just access the pump pulley through the removable 'porthole' in the timing case. Is this a reasonable expectation?
Any other info welcomed.
Thanks
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  #2  
Old December 3rd, 2013, 02:16 PM
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John B.
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It is all explained in the factory workshop manual. Download the manual and read it carefully. If it were me, I would do the timing belt regardless.
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Old December 3rd, 2013, 02:37 PM
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Rick Newman
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x2. My pump is leaking and if I have to pull it, I am going to do the whole thing.
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Old December 3rd, 2013, 03:15 PM
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I haven't done a natural but yes you put the engine tdc and screw in a locking pin into the bell housing and that locks the crank @ the flywheel. You need to be careful when pulling the belt off that the cam sprocket doesn't move.
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Old December 3rd, 2013, 03:35 PM
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Quote:
Originally Posted by Uncle Douglas View Post
I haven't done a natural but yes you put the engine tdc and screw in a locking pin into the bell housing and that locks the crank @ the flywheel. You need to be careful when pulling the belt off that the cam sprocket doesn't move.
Doug, he is referring to a tool that bolts to the pump sprocket holding it in place to allow changing the pump without removing the timing belt. There is a tool you can get for TDIs. As I said though, it is always good to change the belt regardless.
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Old December 8th, 2013, 07:05 PM
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Alistair Davidson
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Thanks alot for the info.
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Old December 17th, 2013, 07:17 PM
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Alistair Davidson
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tried tackling the job today and after removing the fan ducting came up against the 41mm crank bolt holding the harmonic balancer and fan pulley.
As i did not have a 41 mil socket could not continue.
Is the best way to undue this bolt with an impact wrench? (Ive heard of the wrench and starter motor method but sounds sketchy)
Also it seems i need a thin wrench with a 'goose neck' to remove the cooling fan...any input on where or how i can get around this prob?
Thanks again
-beav
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Old December 17th, 2013, 07:22 PM
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Quote:
Originally Posted by Red90 View Post
Doug, he is referring to a tool that bolts to the pump sprocket holding it in place to allow changing the pump without removing the timing belt. There is a tool you can get for TDIs. As I said though, it is always good to change the belt regardless.
i have the kit and have held the gear and belt in place and changed a tdi pump. I'm going to assist with Newman's attack on his.
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