JX crankshaft locking

[multisi]

Peter Russek workshop manual is great for diesel engine work.

[Cecil]

The toothed pulley has a shoulder that the large central hole in the damper pulley locates on so I suspect that is what is sticking. I tend to agree with David ,lots of gentle tapping and wiggling should get it off!

[mioba]

If you are using a hammer then a lump hammer is the way. A normal hammer wont cut it.

With such a high torques bolt a small spanner and hammer also wont cut it - how long is the breaker you are using.

AFAIK you dont need to remove the crank pulley at all to change the timing belt, you need to remove the drive belts for access when removing the timing belt cover. The alty belt is simple - loosen alty tension so it slides down to engine, the PAS belt it very tight and the adjuster minimal - cut it off. To get new PAS belt on - get it tight on both pulleys as much as possible and crank engine shorty to pull it over - noting which way engine cranks so you can tension it the right way - may take a fee goes.

Good luck

[Bryce]

I done mine over the summer and found the hardest part getting the belt back on.

Defo don't need to remove the bolt in the toothed sproket just the four Allen head bolts(no 14)

Make sure you have the fuel pump and cam locked!



Hopefully that might help

[SurfbusReborn]

wow! Thank you very much everyone for your help, particularly cecil and bryce for posting the photos.

I have just been outside tapping away with my copper hammer. The pulley is stuck solid!
Though now I know it should definitely come off, I will come home from work tomorrow armed with a set of pullers. I just wish I'd thought of that today 

@bryce Your workshop manual looks good. Could you let me know what it's called please?

Cheers everyone.

Steve.

[SurfbusReborn]

I done mine over the summer and found the hardest part getting the belt back on.

Defo don't need to remove the bolt in the toothed sproket just the four Allen head bolts(no 14)

Make sure you have the fuel pump and cam locked!

Hopefully that might help

Thank you Bryce,

Just realised this is the Bentley manual, which I have! And did look at    But when the pulley didn't budge I just assumed the picture in the manual was of a different spec. Hey ho. We're getting there, slowly. Thanks.

[SurfbusReborn]

Peter Russek workshop manual is great for diesel engine work.

Thanks multisi, I do have this manual (the one I have is a little handbook). I couldn't find a clear view of the front pulley assembly in this.

[SurfbusReborn]

If you are using a hammer then a lump hammer is the way. A normal hammer wont cut it.

With such a high torques bolt a small spanner and hammer also wont cut it - how long is the breaker you are using.

AFAIK you dont need to remove the crank pulley at all to change the timing belt, you need to remove the drive belts for access when removing the timing belt cover. The alty belt is simple - loosen alty tension so it slides down to engine, the PAS belt it very tight and the adjuster minimal - cut it off. To get new PAS belt on - get it tight on both pulleys as much as possible and crank engine shorty to pull it over - noting which way engine cranks so you can tension it the right way - may take a fee goes.

Good luck

Thanks for the advice. Thanks to all on here I now realise I don't need to remove the crank nose bolt but I'll bear you advice in mind when refitting the vee belts. Cheers.
 

[SurfbusReborn]

Hello,

Thanks for the quick reply.

I am removing the bolt to change the cam belt.

Regards
Steve.

Tap wiggle jiggle , it will come off

Thanks for this photo,

The fuel pump on this engine looks very different to mine. I might be in the market for a recon pump as my van failed the MOT on smoke. I'm starting with new injectors and going see if that fixes things (when I eventually get the cam belt changed and the engine back together!). As there seems to be no JX pumps about I was wondering if the pump on the engine in this photo is some alternative part I could consider? 

[Bryce]

Pretty much all places now sell refurbed pumps based on you sending in your old one in to replace their stock.

You can send it to a guy called diesel Bob who has a Web page and is well thought of and he can refurb it and send your original back.

Sounds like you doing exactly what I had to do! I had a leaking fuel pump and hard starting so took pump off and gave to a diesel specialist near me (£500). You then have to reset the timing which can be a bit fiddly.



That's the manual that had the photo and for setting the timing of pump Google vince Walden (I think) and have a read

[SurfbusReborn]

Pretty much all places now sell refurbed pumps based on you sending in your old one in to replace their stock.

You can send it to a guy called diesel Bob who has a Web page and is well thought of and he can refurb it and send your original back.

Sounds like you doing exactly what I had to do! I had a leaking fuel pump and hard starting so took pump off and gave to a diesel specialist near me (£500). You then have to reset the timing which can be a bit fiddly.



That's the manual that had the photo and for setting the timing of pump Google vince Walden (I think) and have a read

Thanks Bryce,

I'll consider diesel Bob if the new injectors don't do the trick. My van starts and drives fine, it's just very smoky after startup. It does clear eventually. My Son followed me in his van to Busfest this year, and he said there was no smoke at all, but the MOT station said otherwise.
I'd initially thought it might be valve stem seals, but the MOT man suggested injectors.
I timed the pump on my Son's CS recently, so sort of know my way around. Hopefully the JX won't be much different, though I've already got stuck at the crank pulley 
Your manual looks a lot clearer than my Bentley so I will definitely try and get hold of a copy. Many thanks. Steve.

[Cecil]

What a pain ,I am running out of ideas. The rubber damper part of the pulley restricts use of heat I guess also how much force you should put on it with a puller. Fingers crossed some more perseverance works otherwise maybe removing the central bolt should be considered after all .

[clift_d]

Pretty much all places now sell refurbed pumps based on you sending in your old one in to replace their stock.

You can send it to a guy called diesel Bob who has a Web page and is well thought of and he can refurb it and send your original back.

Sounds like you doing exactly what I had to do! I had a leaking fuel pump and hard starting so took pump off and gave to a diesel specialist near me (£500). You then have to reset the timing which can be a bit fiddly.



That's the manual that had the photo and for setting the timing of pump Google vince Walden (I think) and have a read

Thanks Bryce,

I'll consider diesel Bob if the new injectors don't do the trick. My van starts and drives fine, it's just very smoky after startup. It does clear eventually. My Son followed me in his van to Busfest this year, and he said there was no smoke at all, but the MOT station said otherwise.
I'd initially thought it might be valve stem seals, but the MOT man suggested injectors.
I timed the pump on my Son's CS recently, so sort of know my way around. Hopefully the JX won't be much different, though I've already got stuck at the crank pulley 
Your manual looks a lot clearer than my Bentley so I will definitely try and get hold of a copy. Many thanks. Steve.

I've sent you a PM with the download link for PDFs of the two JX engine manuals. FYI the JX was never one of the engines offered to US consumers, hence it isn't covered by Bentley.

The only other source of JX service information is the Russek manual, which was mentioned above, and this has been reprinted by Just Kampers and can be obtained here.

In terms of the timing belt, the service manual shows the use of a special tool (VW210) to set the correct tension - you might be able to pick up an original version of this tool on eBay, or one of the copies that are available from places like dieselkontor. My understanding is that it's also recommended to replace the tensioner pulley at the same time as the timing belt. You should be able to get everything you need from Brickwerks.

[SurfbusReborn]

Many thanks for this.

Belt tensioner is on order, but I was going to wing the tension, I'll see if I can get hold of the tension tool for the weekend.
I'll grab the pdf's this evening.

So impressed with the support from this community. Thank you.

[mrhutch]

I've never used a proper tensioning tool, I've got a pair of long nose pliers ground down to fit!