Injection pump bracket fractured

[romie]

... but as I've got a few days until I source/repair bracket, I'll knock up the puller to be more mechanically sympathetic.

Fantastic diagram, just need to go shopping

[CitroJim]

Hey, nice pictures!!

Thanks Romie

Erm, over a year or so ago I removed the pump from the sprocket by, er, taping a screwdriver down each side of the sprocket. It worked very well I'll add. Didn't seem to put any unwanted pressure anywhere and the pumps been perfectly fine since then. I'm I a bad person? :p

Well, I'm always a bit iffy about using any other method to remove the sprocket other than a puller but I do know some use hammers but how I don't quite understand

Never a bad person!!! But I'd always be worried about bending the pump driveshaft using different methods.

I very much doubt it but I hope your method didn't crack the cradle. Where is the crack exactly?

I'm more inclined to agree with Lighty on a potentially missing or loose rear mount or a missing taper boss on the bolt as the root cause. That bolt is special and if replaced by a normal bolt the integrity of the pump mount will be compromised. It's critical as the pump really vibrates hard in use and is one of the main contributors to the noise the engine makes. If you ever see a pump running on a test stand being calibrated you need to wear ear defenders. The din they make is unbelievable!

Also critical is to have the special serrated washers under each of the four pump mounting nuts and do them up moderately tightly. Not absolutely FT but tight enough to ensure they cannot vibrate loose...

once you find the timing hole you never forget..

Very true Paul, very true

[Spaces]

I agree about the comments regarding missing taper boss, washers etc. The pumps need to be mounted absolutely correctly (don't ask how I know..).

By the way, how is the heated tank working in this cold weather?

[romie]

I agree about the comments regarding missing taper boss, washers etc. The pumps need to be mounted absolutely correctly (don't ask how I know..).

By the way, how is the heated tank working in this cold weather?

Right. So that's the approach

I'm going to remove the pump and check out the four mounting points.

What's the taper boss? I presume that's where the pumps drive shaft + woodruff key fits into? Isn't that the pumps sprocket?

Once pump is off I'll get some photo's of the fracture up here...

Cheers!!



--
On the veg tank question:
The heated veg tank is absolutely amazing!! As it and all the lines are heated via the coolant, it gets up to 60-70oC very easily and keeps it's temperature nicely over night. In fact it helps to heat the ip and filter
I'm thinking of getting a big vehicle, 'landrover 101', transit? To use as a make-shift camper and get a big ol hot water tank set up to have showers using the same method!! Hahah. Do other touring vehicles use the coolant to heat up their hot water? Or do they not do this?

[jgra1]

I agree about the comments regarding missing taper boss, washers etc. The pumps need to be mounted absolutely correctly (don't ask how I know..).

I ran my first TD (309) for 2 years with the back bolt missing, unknowingly..

I had to carry the injector pipes around with me, as one of those would snap every couple of months.. I sold the car to a friend, and even passed pipes and instructions to her

live and learn.

[CitroJim]

What's the taper boss?

It's a special bolt with a tapered shank just below its head that is used to secure the rear pump mount to the cradle. The cradle has a tapered housing especially for this bolt...

[romie]

I have seen these brkts fail if the pump tail end fixing is not fitted , or left loose, the three front fixings are not enough on their own to hold the pump.

Nice one Lighty!

BAM.

Yes! It seems that the tail end bolt is not in there!

Wasn't put back in/vibrated out... ? Dunno. But not there.

Fantastic deduction

This is good as I was very worried to why the bracket had failed.

Haha, nice thinking guys!!

So this is what happens after a year of not having the tail end bolt in and then you replace the timing belt with a nice new tighter version.

...It may explain why your cam belt was running over the edge of the pulley.

So yes is hopefully why the belt was riding off the ip sprocket :/

What's the taper boss?

It's a special bolt with a tapered shank just below its head that is used to secure the rear pump mount to the cradle. The cradle has a tapered housing especially for this bolt...

Going to have to find a new special tail end bolt as well then! Anyone got a part number?

:/

After removing the injector pipes the pump just came away in my hand. Didn't have to undo ANY of the bolts securing the pump to the bracket!! Only thing holding the pump and timing belt in place was the battle between the timing belt pulling it one way and the injector pipes pulling the other! Think one more start and the pistons would have tried nailing the valves through the cam cover :/

...once you find the timing hole you never forget..

I found that damn timing hole in the flywheel last night as well >:D 8mm metal bar would not go through, think it's slightly smaller. 7mm?

It's going to give me a chance to replace the glow plugs at least.

Cheers!

[RichardW]

You got to be lucky that wasn't a smashed cam job....!

service.citroen lists these parts (in assembly order from outside the bracket to in):

Part Number Description Quantity Price excl. VAT Price incl. VAT Total incl. VAT
0000192333 SUPPORT SCREW 6.15 GBP 7.38 GBP 7.38 GBP
0000696213 FLEXIBLE WASHER 0.15 GBP 0.18 GBP 0.18 GBP
0000694779 PLAIN WASHER 0.44 GBP 0.53 GBP 0.53 GBP
0000192317 CENTRING PUMP 3.52 GBP 4.22 GBP 4.22 GBP
(Bracket)
(Injection pump)
0000696213 FLEXIBLE WASHER 0.15 GBP 0.18 GBP 0.18 GBP
0000693238 HEXAGONAL NUT 0.62 GBP 0.74 GBP 0.74 GBP

[romie]

Hey cheers!

Citroen were confused to what I was after, they're emailing me diagram and part numbers.

The bush thingy is still in the bracket, can that be re-used? Spose that would be the 'Centring pump' thingy?

£7.38 for a bolt!! (or screw as they call it). omg!

8|

[romie]

Looking at the picture I think the nut that goes on the screw is part number - 192318 - diam 8x125?

Fingers crossed I can find these at breaker with the bracket

Thanks RichardW

[citroenxm]

Ive no doubt got these amoungst my masses of bolts in the shed.. DO NOT ask my to find one though - it could take days. This is of course only if the dealer comes back with NFP.. or NLA..

[romie]

cheers Citroenxm, you'll be pleased to hear I've found a breaker with one. In situ mind. Am going to have to take tools, (including the bent spanner) to remove pump to get to bracket.

Plus side is I should be able to get the bolt n all

[KennyW]

Romie,

I have spare pump bolts which i bought when i had my fun with the Bosch pump.

They are the ones at the front Item 71 in the citroen Part list.

If you require same let me know. Postage won't be a lot.

Kenny

[romie]

Cheers KennyW, I'll figure out if everything is 'gettable' from this car tomorrow

Many thanks, good to know if I get stuck!