Reiny Posted September 15, 2013 Share Posted September 15, 2013 My injection pump has just sprung a rather big leak from somewhere towards the rear end. I have booked the car in for a fuel pump overhaul but that means waiting until the 23rd. Specialist told me that if I remove the pump myself I can get it done some time during this week. Should I remove it myself? What is involved? The biggest job I have done on a 300tdi is replacing the timing belt. Is it a DIY job or should I be patient and let experts do it? Quote Link to comment Share on other sites More sharing options...
dailysleaze Posted September 15, 2013 Share Posted September 15, 2013 It's not too involved: http://youtu.be/nwJYhFeAs8k Quote Link to comment Share on other sites More sharing options...
Reiny Posted September 15, 2013 Author Share Posted September 15, 2013 I've watched this video but this includes the special tool (which I don't have). Is it just a matter of removing the timing belt and pulley? Quote Link to comment Share on other sites More sharing options...
steve b Posted September 15, 2013 Share Posted September 15, 2013 Yes , remove the pulley from the hub by taking out the three bolts , not the centre nut . then it's a straight forward case of removing the pipes , support bracket and then the three bolts that hold the pump to the timing cover cheers Steveb Quote Link to comment Share on other sites More sharing options...
Reiny Posted September 15, 2013 Author Share Posted September 15, 2013 Ok, the unit is now lying in a box on the floor, totally surrounded by loads of newspaper and plastic bags. Took just under 2 hours to remove. That's not too bad. One thing is worrying me though. When I tried to remove the timing pin from the pump, it wouldn't budge. Therefore I held the centre bolt and moved it a tiny bit to remove the pin. When I let the centre bolt go, the hub sprung by about 5mm to the left (towards 10 o clock). I have not tried to touch it. Is it a cause for concern (considering that the pump is going to be overhauled)? Quote Link to comment Share on other sites More sharing options...
western Posted September 15, 2013 Share Posted September 15, 2013 that's normal for the FIP to spring when the timing pin is removed. the reconditors will set i all up when the do the bench pressure test after rebuild. Quote Link to comment Share on other sites More sharing options...
vulcan bomber Posted September 15, 2013 Share Posted September 15, 2013 Ok, the unit is now lying in a box on the floor, totally surrounded by loads of newspaper and plastic bags. Took just under 2 hours to remove. That's not too bad. One thing is worrying me though. When I tried to remove the timing pin from the pump, it wouldn't budge. Therefore I held the centre bolt and moved it a tiny bit to remove the pin. When I let the centre bolt go, the hub sprung by about 5mm to the left (towards 10 o clock). I have not tried to touch it. Is it a cause for concern (considering that the pump is going to be overhauled)? Thats normal, its because the pump when held in the timed possition is approx halfway through injecting fuel to number 1 cylinder. Quote Link to comment Share on other sites More sharing options...
Reiny Posted September 16, 2013 Author Share Posted September 16, 2013 Sorry to be a pain but next question: crankshaft front oil seal. It is leaking. Can anyone give me an idiot-proof walk through how to go about replacing it? Quote Link to comment Share on other sites More sharing options...
vulcan bomber Posted September 17, 2013 Share Posted September 17, 2013 Remove the timing belts bottom pully, then the seal is looking at you. Quote Link to comment Share on other sites More sharing options...
Reiny Posted September 17, 2013 Author Share Posted September 17, 2013 I'm really going to be a pain in the neck here friends but I've come to some grief. Crankshaft sprocket came out with no problems. Just screwed 2 bolts and tugged the sprocket out by hand. Seal was a bit difficult to remove but it gave way. New seal in, o-ring in pushed procket in, put timing belt on blah blah bhal, fired up the engine for a few seconds with front cover off, turned engine off and to my horror, found the timing belt slipping off the FIP sprocket by 3.5mm. In a nuthsell, I don't believe i pushed the sprocket in far enough. I tapped it in gently with the wooden handle of a handle (and tapped the head of the hammer lightly with another hammer). it didn't go any further in than it did by hand so i thought it was in place. Evidently, it wasn't. Now, I have another question regarding the o-ring. When I pulled the sprocket out, the o-ring was seated within the sprocket. When I tried to fit the sprocket back, the o-ring kept it from slipping over the cranskhaft so I removed the o-ring and pushed it in as far as I could. Where am I supposed to put the o ring? In the sprocket or on the end of the crankshaft? Quote Link to comment Share on other sites More sharing options...
western Posted September 17, 2013 Share Posted September 17, 2013 page 219 ITEM 8 is the crank front oil seal, http://www.retroanaconda.com/landrover/parts_books/110/3_engine_200TDI_300TDI_V8_p168-299.pdf page 215 item 10 is the 'O' ring seal http://www.retroanaconda.com/landrover/parts_books/110/3_engine_200TDI_300TDI_V8_p168-299.pdf the O ring just slides onto crank but must be fitted over the timing gear woodruff key, the timing gear then pushes the O ring against the oil seal, as far as I can extract from my 300tdi workshop manual info. Quote Link to comment Share on other sites More sharing options...
nickwilliams Posted September 17, 2013 Share Posted September 17, 2013 I suspect the o-ring is the reason the sprocket is out of alignment. You need to apply a firm, steady force to get the ring to seat inside the sprocket, hitting it with a hammer gently won't do it, and if you hit it hard enough to seat properly then you'll almost certainly damage the O-ring. If you slide the O-ring on to the end of the shaft first, and then slide the sprocket over the top and push, you'll feel the sprocket move as the o-ring seats in the sprocket. If you don't feel it, it's probably not seated properly. Quote Link to comment Share on other sites More sharing options...
Reiny Posted September 18, 2013 Author Share Posted September 18, 2013 Thanks a lot. Will try this evening. fingers crossed. Quote Link to comment Share on other sites More sharing options...
Reiny Posted September 19, 2013 Author Share Posted September 19, 2013 Job done I'm a happy chappy Quote Link to comment Share on other sites More sharing options...
western Posted September 19, 2013 Share Posted September 19, 2013 Job done I'm a happy chappy good job Quote Link to comment Share on other sites More sharing options...
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