2.5L DEFENDER 90 (1990) TURBO DIESEL INJECTOR PUMP REMOVAL

dgale1979 · Jan 4, 2019

HELP!!
My defender 90 recently failed its MOT due to a leaking injector pump.
I have removed all injector pipes, nuts etc.. but cannot remove the pump itself ?
I purchased an engine timing kit but this doesn't seem to fit correctly even though my vehicle is listed as compatible?
Would really appreciate some advice/input on moving forward.
I have attached some photos to hopefully help.

dieseldog69 · Jan 4, 2019

You need to remove the crank pulley, remove the front of the timing case, time the engine, remove timing belt, remove injector pump pulley and then the pump should slide out on the proviso that all 3 securing nuts are removed from the studs and the support bolts removed from the block.

Does this help?

If not, go into the engines section an ask there

dgale1979 · Jan 4, 2019

Ouch
Not the answer I was hoping for ‍

Many thanks though will look into it in finer detail

Britcyclerider · Jan 4, 2019

It's not as difficult as it sounds. You can lock the pump with a twist drill (9.5 mm?). The big challenge may be getting the crank pulley bolt out.

Britcyclerider · Jan 4, 2019

I assumed in my response you have a 200tdi, but having re-read the posting, sounds like you have a 19j TD. You may need a different locking pin size for that.

Flossie · Jan 4, 2019

Hang on...
Isn't the kit in the last pic the one you can use to hold the FIP pulley in place and thus remove the FIP without stripping the timing case out?
Looks like the big nut is still on the pulley of the fip too .
I've never used one of those kits though so I'm unsure if that kit is correct but you can buy them for sure.

dgale1979 · Jan 4, 2019

Britcyclerider said:
I assumed in my response you have a 200tdi, but having re-read the posting, sounds like you have a 19j TD. You may need a different locking pin size for that.

2.5 na TD Engine

Britcyclerider · Jan 4, 2019

Na (naturally aspirated) suggests it has no turbo. It can't be NA and a Turbo Diesel! Can you see a turbo?

dgale1979 · Jan 4, 2019

Flossie said:
Hang on...
Isn't the kit in the last pic the one you can use to hold the FIP pulley in place and thus remove the FIP without stripping the timing case out?
Looks like the big nut is still on the pulley of the fip too .
I've never used one of those kits though so I'm unsure if that kit is correct but you can buy them for sure.

Correct on the kit but it is too big to fit into the casing, I managed to fix it in reverse hoping to at least keep everything in place, this was after removing the internal nut. I then tried to use the bolts to push the pump off as seen in youtube videos but felt there was too much resistance to continue, hence my cry for help!
The pump moves left to right but not backwards as required, Seams like additional fixings somewhere out of sight?

dgale1979 · Jan 4, 2019

Britcyclerider said:
Na (naturally aspirated) suggests it has no turbo. It can't be NA and a Turbo Diesel! Can you see a turbo?

My Bad just a 2.5 TD

Flossie · Jan 4, 2019

Wrong or poorly made kit then maybe?
From memory there is 3 nuts to the timing case and a steady bracket to the block.
Where is the leak? Some can be done in situ but not the front pulley one.

Hippo · Jan 4, 2019

Welcome to the forum

Flossie · Jan 4, 2019

Hippo said:
Welcome to the forum

I never noticed the forum header

Hello and welcome from me too

2.5L DEFENDER 90 (1990) TURBO DIESEL INJECTOR PUMP REMOVAL

dgale1979

New Member

Attachments

dieseldog69

Well-Known Member

dgale1979

New Member

Britcyclerider

Well-Known Member

Britcyclerider

Well-Known Member

Flossie

Well-Known Member

dgale1979

New Member

Britcyclerider

Well-Known Member

dgale1979

New Member

dgale1979

New Member

Flossie

Well-Known Member

Hippo

Lord Hippo

Flossie

Well-Known Member

Similar threads