Cannot remove fuel pump sprocket nut

flanagaj · Feb 1, 2013

I have been trying in vain to remove the fuel pump sprocket nut on our TD4. The nut turns ever so slightly but never seems to undo no matter how many times it seems to move.

Could it be that the shaft inside the pump is turning as well which is why I cannot undo it?

mick 1986 · Feb 1, 2013

I wouldn't say so mate, not unless you have tried to remove the fuel pump by pulling it!???

Try getting someone to push the pump into its housing while you undo the nut.

landowner · Feb 1, 2013

Do you need to lock it in position with a drill bit or something like a tdi?

If you take that big nut off a tdi pump and disturb the plate it means retiming the pump with gauges an techniklle stuff

mick 1986 · Feb 2, 2013

landowner said:
Do you need to lock it in position with a drill bit or something like a tdi?

If you take that big nut off a tdi pump and disturb the plate it means retiming the pump with gauges an techniklle stuff

It doesn't on the TD4. It's a sprocket that spins a shaft on the HP pump, there's no timing involved on these engines.

Thinking about it, I may have used the outside part of the special tool to lock agains that sprocket while I stuck a socket up the inside of it to turn the nut!? I can't remember exactly.

Ian jones · Feb 2, 2013

mick 1986 said:
It doesn't on the TD4. It's a sprocket that spins a shaft on the HP pump, there's no timing involved on these engines.

Thinking about it, I may have used the outside part of the special tool to lock agains that sprocket while I stuck a socket up the inside of it to turn the nut!? I can't remember exactly.

I was told , two special tools were required one to retain the timing sprocket , and the second to extract the pump !

flanagaj · Feb 2, 2013

Ian jones said:
I was told , two special tools were required one to retain the timing sprocket , and the second to extract the pump !

Looking at the manual now and you remove the nut first and then use the special tool. States the same in the Rave manual

Ian jones · Feb 2, 2013

flanagaj said:
Looking at the manual now and you remove the nut first and then use the special tool. States the same in the Rave manual

Hope you get it sorted

DD3 · Feb 2, 2013

Ian jones said:
Hope you get it sorted

I cant offer specific help but in general terms, if it is not making sense, then stop. Step away from it and re group! Its great to have a go but need to set limitations. Good luck with it.

Optimus Prime · Feb 2, 2013

DD3 said:
I cant offer specific help but in general terms, if it is not making sense, then stop. Step away from it and re group! Its great to have a go but need to set limitations. Good luck with it.

that's all he needs, a load of management speak but no actual help !

DD3 · Feb 2, 2013

Optimus Prime said:
that's all he needs, a load of management speak but no actual help !

Well, help him then!!! So far cant see that the forum really has answers on this

mick 1986 · Feb 2, 2013

Ian jones said:
I was told , two special tools were required one to retain the timing sprocket , and the second to extract the pump !

It's the same tool. The outside of the tool screws into the 17mm hex plug threads, this holds the sprocket still. The second part then threads into this and is screwed up tight, it has a bolt running through it, you tighten the bolt and it pushes the tapered shaft out of the sprocket.

I can't remember exactly how I got my nut off, but what I can remember is when I rebuilt it all the pump was pushed in by hand and the nut placed inside a socket, then just tightened down. No special tools needed.

Ian jones · Feb 2, 2013

mick 1986 said:
It's the same tool. The outside of the tool screws into the 17mm hex plug threads, this holds the sprocket still. The second part then threads into this and is screwed up tight, it has a bolt running through it, you tighten the bolt and it pushes the tapered shaft out of the sprocket.

I can't remember exactly how I got my nut off, but what I can remember is when I rebuilt it all the pump was pushed in by hand and the nut placed inside a socket, then just tightened down. No special tools needed.

Duely noted

flanagaj · Feb 2, 2013

I got there in the end. The secret is to extend the ratchet with another bar and give it a sharp shove. That seemed to do the trick

mick 1986 · Feb 2, 2013

flanagaj said:
I got there in the end. The secret is to extend the ratchet with another bar and give it a sharp shove. That seemed to do the trick

Have you managed to get it sorted then mate?

teddywood1 · Feb 2, 2013

with no special tool Great sorry i have not taken a master pump off so could not help

flanagaj · Feb 3, 2013

mick 1986 said:
Have you managed to get it sorted then mate?

Hi Mick, I have rebuilt the pump with the service kit and put it all back together. Just trying to get the alternator built fitted.

I did in the end take off the starter as I did not have a socket extension bar of the correct length without it fowling the starter. Very quick to remove it.

Anyway, I am hoping the problem was the pump as there was one seal which had split both the inner rubber out outer nylon washer. So I suspect given the higher pressures involved was causing the pump to leak.

There was a definite leak as diesel was dripping off the engine sump and the underbelly tray was very wet.

Will report back later on today with the results. Fingers crossed!

mick 1986 · Feb 3, 2013

flanagaj said:
Hi Mick, I have rebuilt the pump with the service kit and put it all back together. Just trying to get the alternator built fitted.

I did in the end take off the starter as I did not have a socket extension bar of the correct length without it fowling the starter. Very quick to remove it.

Anyway, I am hoping the problem was the pump as there was one seal which had split both the inner rubber out outer nylon washer. So I suspect given the higher pressures involved was causing the pump to leak.

There was a definite leak as diesel was dripping off the engine sump and the underbelly tray was very wet.

Will report back later on today with the results. Fingers crossed!

I would expect that was the problem then, none of my seals had any visible damage to them. Did you clean all the seal seats?

flanagaj · Feb 3, 2013

mick 1986 said:
I would expect that was the problem then, none of my seals had any visible damage to them. Did you clean all the seal seats?

I replaced all of the seals and gave the pump a good clean. The vehicle seems to have regained a considerable amount of power too. SO the leaking pump must have been reducing fuel pressure and making the vehicle run sluggish for some time.

Thanks

Cannot remove fuel pump sprocket nut

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landowner

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