Technical 1996 fiat ducato 2.5tdi (sofim) turbo actuator question

[jackwhoo]

I found some info on early similar iveco engine.
5 degrees before tdc (cylinder 1 compression stroke) plus or minus 0.5 degree . The Bosch ve pump piston should read 1mm further out than the lowest measurable figure.

these numbers appear sensible but did not come from technical documents.

The injection sprocket has a hole (6mm?)
That in belt change position should align with another hole in the belt casing behind sprocket. A locking pin should be slid through sprocket hole into casing hole to lock the position while belt being changed.


Plus a number of different sized timing belt were used on the 8140 engine during the years-again Essential to use the correct belt

 

[bugsymike]

I found some info on early similar iveco engine.
5 degrees before tdc (cylinder 1 compression stroke) plus or minus 0.5 degree . The Bosch ve pump piston should read 1mm further out than the lowest measurable figure.

these numbers appear sensible but did not come from technical documents.

The injection sprocket has a hole (6mm?)
That in belt change position should align with another hole in the pump body. A 6mm locking pin should be slid through sprocket hole into pump hole to lock the position while belt being changed.

I would not be surprised if the locked position = 1mm pump piston height. It is a lot easier during production of pump to set the locked position of pump at injection point than set timing of every engine using a DTI.

It is essential NOT to undo the pump sprocket nut or the pump locked point will be lost and need resetting using a DTI.

Plus a number of different sized timing belt were used on the 8140 engine during the years-again Essential to use the correct belt

I agree with you, 5 degrees before TDC corresponding with 1mm injector pump piston travel matches what my Diesel Technical Data photo from earlier, although it says 1mm for the non turbo and 1.3mm for the turbo versions.
Re the 6mm locking pin/drill bit that is what I have used on many Ivecos when doing cam belt kits and had no issues with injector timing.I found on those the guide bearing size changed and belt had to be matched in length due to that.
As you say no undoing the pump sprocket nut.

 

[bugsymike]

So assuming??? cambelt timing correct then if DTI gauge zeroed in correct position as per that earlier photo then a lift of 1-1.31 mm should be about correct.

 

[jackwhoo]

So assuming??? cambelt timing correct then if DTI gauge zeroed in correct position as per that earlier photo then a lift of 1-1.31 mm should be about correct.

I agree if; DTI and adaptor is available , can be fitted reasonably easy, crank tdc can be accurately set, then pump piston lift should be within that range. If not then pump timing incorrect and previous belt replacement needs rechecking completely.

 

[jackwhoo]

In tank fuel pipe pick up strainer checked for blockage?
Not related to timing

 

[jackwhoo]

This guy only has one size of hammer

Some actions "not best practice" but good points on belt covers , washers etc . He doesn't use the correct crank pulley timing mark at first but spots error and corrects in video. He does appear to use correct locking hole on pump pulley and pump (5mm) after a couple of tries.
Funny he mentions other people's timing marks all over the place

 

[bugsymike]

This guy only has one size of hammer

Some actions "not best practice" but good points on belt covers , washers etc . He doesn't use the correct crank pulley timing mark at first but spots error and corrects in video. He does appear to use correct locking points on pump pulley after a couple of tries.
Funny he mentions other people's timing marks all over the place

I am assuming the A class is a bit more restricted for access?
I love the HSE aspect.

 

[jackwhoo]

Ignor what I said about pin through injection pump belt sprocket locking pump at correct postion.....that is for Bosch ve pump on different engines-apologies.

Locking Pin locks the belt sprocket attached to driveshaft for the accessory housing . The accessory housing drive shaft does drive the inj pump via a splined connection with a master spline.

The sofim 8140 is a special beast

Please see following video.

Shows a lot including use of dti to set timing

 

[MrkT]

In tank fuel pipe pick up strainer checked for blockage?
Not related to timing

yes i cleaned it last week Jack. (it was dirty mind!)

 

[bugsymike]

Ignor what I said about pin through injection pump belt sprocket locking pump at correct postion.....that is for Bosch ve pump on different engines-apologies.

Locking Pin locks the belt sprocket attached to driveshaft for the accessory housing . The accessory housing drive shaft does drive the inj pump via a splined connection with a master spline.

The sofim 8140 is a special beast

Please see following video.

Shows a lot including use of dti to set timing

Excellent video, a picture better than a 1000 words. The fine adjustment is just the slotted mounting holes of pump once nearly there.
I see their manual gives an even higher advance figure in mm, 1.41mm? I did mine like that when on a stand after rebuilding engine 20 odd years ago, the video would have helped then.
Soooooo much easier like that, than in situ on a A class eh!

 

[MrkT]

Excellent video, a picture better than a 1000 words. The fine adjustment is just the slotted mounting holes of pump once nearly there.
I see their manual gives an even higher advance figure in mm, 1.41mm? I did mine like that when on a stand after rebuilding engine 20 odd years ago, the video would have helped then.
Soooooo much easier like that, than in situ on a A class eh!

yes ours has very little access.....i think almost as much as the man with the hammer! (just doable) also from the top of the engine there is about an inch gap between that and the bulkhead.......so everything on the back of the engine the access is from underneath only! (and at arms length!)

 

[MrkT]

i re-adjusted the Bosch VE pump boost pressure housing again today after reading of some good results elsewhere.........
As read,i set the bottom toothed wheel 2 full turns in (clockwise) and set the top hat (diaphragm)with its conical shaped slide 60 degrees anti clockwise from standard.(before i'd turned it a quarter turn clockwise)
(the bottom toothed wheel gives you more fuel low down,the diaphragm part gives you more at higher boost.)
i marked them so i can return to standard if needed.......however,i don't think i ever will!
The van now has quite a bit of low down grunt!! a hill i struggled up last week from second to first gear,i can now accelerate up in third...........................
it has quite a bit of noticeable low down boost now and no smoke at all!
(this type of tweak affects the fuelling when on boost only and should not cause any harm)
if the pump timing is indeed out,then it can stay like that.
It could do with a little more top end boost if i'm being picky,but i'm quite happy with the results and going to just leave it as is for now.
it is a large tag axle 4 ton motorhome.......and not a Ferrari after all.
A big thank you to all for your contributions (it is very much appreciated).

 

[jackwhoo]

Thanks for updates.
If it moves ok sounds ok with no or very little smoke then injection timing probably fine.

There is a screw in the Bosch ve pump which is easily adjusted and adjusts total fueling - sounds like something you may enjoy.

Cheers
Jack

 

[jackwhoo]

That age diesel design under full load and boost I would expect to see some black smoke

 

[MrkT]

That age diesel design under full load and boost I would expect to see some black smoke

If there is Jack it's not noticeable........This engine has only done a genuine 52k,so may be that helps?
yes i know about the screw on the pump,but don't want to mess with that one really........i want reliability more.