Eco blue intermediate cog issue.

[hi_tower]

I was changing the wet belts on my 2019 custom today and all was going well. I got the new belt on and I was turning the engine over by hand until the timing marks aligned again (14 turns?). I heard a metallic ping and noticed the thin cog on the back of the intermediate cog is rattling around loose. I assume this isn’t how the thin cog is supposed to be. I didn’t notice it rattling around loose until I heard the ping. Anyone know how to re attach the two cogs?

[hi_tower]

After much research and finding photos of the intermediate/idler wheel on eBay it seems the thin gear on the back is sprung into the back of the bigger wheel like a big circlip and I’ll need to remove both and clip them back together. Does anyone know if the bolt is re usable or a torque figure? It says BUFO 10.9 on the head which is just a high tensile bolt from what I’ve read.

[hi_tower]

https://flic.kr/p/2pK9tEA
https://flic.kr/p/2pK9tEq
So the idler wheel is removed now. I don’t know if the thin cog should be loose as in the first image of rotated so it kind of bayonets under the tabs like I’ve done in the second image. If it’s in the fixed bayoneted on position it reveals the locking pin hole which is covered when it’s in the loose position.
Now the idler wheel is off I can see another thin gear loose on the back of the pump cog. I’m in a bit of a fix now as I have no van for work until I get this sorted.
Anyone had one of these apart before and noticed loose gear wheels jangling about?

[metalworker0]

All i can suggest is you watch every 2.0l wet belt change video on you tube , there are about half a dozen or so.

all the best.mark

[metalworker0]

And having not taken one apart , i'm not quite familiar
but does that cog removal require a new bolt when installed...something about diamond coated flange bolt - antislip ..one use only comes to mind

and look at picture ..i may be wrong ..does this cog drive the fuel pump ..note oil seal "hr1" in the picture..i would imagine that gets crushed and is one use only

https://www.catcar.info/ford/?lang=en&l ... QwMjUrMTMz

no one knows the torque for this bolt ..we have looked extensively in the last couple of weeks.

all the best.mark

[hi_tower]

Thanks for the reply mark.
I’ve watched loads of YouTube videos before I decided to take on the wet belt job myself. I rewatched most of them last night for wobbly thin gear wheels but I didn’t see any.
I haven’t dared remove the fuel pump wheel yet as I believe it’s not that simple to re time when you put it all back together. The thin cog behind the fuel pump cog can fall right back against the crank case and rotate independently which can be right?
https://flic.kr/p/2pK4GuN
https://flic.kr/p/2pK4Gvp
In the second image you can see its fallen back & down and turns on its own. Interestingly there is no thin second cog shown in the image you linked to.

[metalworker0]

Don't think there is timing on the pump ..as its tdci ..only tddi and the old manifold injection have timing ..as the timing of the squirts is done on the injectors electronically by the ..what is it called a PCM?

some pics of sprocket here ...and a sleeve

https://www.ebay.co.uk/itm/285778936645

another picture here

https://i.ytimg.com/vi/U2CoYOXwnrw/sddefault.jpg

another here

https://www.aaronsautos.co.uk/wp-conten ... g_7754.jpg

im not learned enough to explain the double gears,, and no matter how many pics i see, i cant actually see them and feel them..and see what's going on.
Could be a a paralleled beveloid gear, for reasons of quietness and rid it of backlash

explained here

https://www.sciencedirect.com/science/a ... 4X24000508

or
You can see a maybe piece of rubber in it ..or is it steel, that means not beveloid ..but a damper ...between both gears ..another anti-backlash device ..or there for quietness. .in your very first picture

as far as i can make out, backlash is taken up by the rubber once in motion, so meant to move.

https://i.ebayimg.com/images/g/Lh4AAOSw ... -l1600.jpg

we are only beginning to become familiar with this engine ..and sorry, its a lot of guess work so far .


all the best.mark

[metalworker0]

I've looked at the parts diagrams both the pump and the cam belt ones..they are not accurate/ not detailed enough, to even show the gears as double ..

They want to sack the computer graphics guy who draws the diagrams ..as they are only half as good and detailed as the old ones that were around ten years ago or before.

all the best.mark

[metalworker0]

if the gear is meant to be permanently attached to other gear by this rubber --- i can not see that either in pictures anywhere ..or find pictures of it seperated ..only yours.

so its all a guessing game.

all the best.mark

[My van hates me]

Not sure about in operation but if you google transit custom crankshaft idler sprocket it is generally shown with the bayonets engaged.

[hi_tower]

Not sure about in operation but if you google transit custom crankshaft idler sprocket it is generally shown with the bayonets engaged.

Could you post a link to an image of a sprocket with the bayonets engaged? I’ve been scouring the internet for hours today and haven’t found one with the bayonets engaged.

Like this one I took.

[hi_tower]

if the gear is meant to be permanently attached to other gear by this rubber --- i can not see that either in pictures anywhere ..or find pictures of it seperated ..only yours.

so its all a guessing game.

all the best.mark

There is no rubber part in the idler pulley. Just a thick cog wheel with a thinner one directly contacting the back of it. I’ve been looking at photos of these all afternoon on the internet and the thin cog is loose on every one of them not bayoneted together. The thin cog on the fuel pump is more of a concern because this can fall completely off the back off the big cog & revolve independently.
I’ve ordered a manual on cd which I hope will give some answers. If not I’ll ask for some advice from the service manager when I go to buy a new idler pulley bolt, they can only tell me to bugger off I suppose.

[My van hates me]

Not sure about in operation but if you google transit custom crankshaft idler sprocket it is generally shown with the bayonets engaged.

Could you post a link to an image of a sprocket with the bayonets engaged? I’ve been scouring the internet for hours today and haven’t found one with the bayonets engaged.

Like this one I took.

https://www.ebay.co.uk/itm/285778936645 ... xUQAvD_BwE

[My van hates me]

https://www.ebay.co.uk/itm/225901734355 ... 6IQAvD_BwE

[My van hates me]

https://izap24.kz/tovar/27459833_koleso ... -ymfs.html