Pipebender

Well a fruitful day, and thank you for your help, got the engine turning over and valves/tappets set up , everything lined up a treat. engine now starts but not running well , won't respond to any throttle barely ticks over, sound like it is on the cusp of running correctly, I suspect that the pump although dead on the marks and locked when set up, may after the trouble I have self inflicted need to come off or is a revolution out if that's possible, going to sleep on it tonight. Diesel is all bled through etc, and the smoke out the exhaust is prolific and stinks off un burnt fuel so it's not right, but i'm now happy with the crank and cam timing and now know there are two slots !!!! We have a very good diesel injection specialist not far away who reconded the pump when I did the original rebuild, nobody knows his real name they just call him Bosch !! so I think I may re strip down and whip the pump off and let them give it the once over so I know it's correct and set up without any internal damage, i have been thinking of getting the injectors reconed as well , more for peace of mind, this time of year the landy does'nt get over used, but after harvest I will need it spot on for the winter etc, new injectors are eye watering for the 200, and as the engine was well second hand with no history when I bought the engine nearly ten years ago I figure they have probably earnt some tlc. thanks again for the help it saved me whipping the head off which was what i was going to do next to get the true TDC.

Hmm very interesting, I will mark the slot i have with a bit of paint and spin the the engine and see if i can find another slot, when i set it up originally i had the head off and used a dial gauge so I knew TDC was dead on, obviously with the head on I have been relying on the slot to give tdc, On the crank balancer there are TDC marks but I couldnt find a ref point that it lined up with on the housing, I will take another look , and as soon as it stops raining I will be underneath, if the two slots is the case then that would account for all my woe's. i will let you know.

Yes the engine turned with the pin still in the pump, so it must have jumped on the belt I assume to get out of time and bend the push rods, on the fly wheel I'm not aware there was another slot, the one I'm using looks the same width as the locking screw, i don't remember there being two from when i did the rebuild and set it all up back then, if there is it would appear that i'm in the wrong one to be still hitting the valves. is this at 180 from the other.

Ok , we have had a big uupps momentBackground is that the water pump was leaking on my 200 tdi disco engine in my 90, so while i'm in there I thought to put a new timing belt etc on as it's not been done since my engine rebuild 30k ago.Got everything locked off pump pin and flywheel locking screw, swapped belt, tensioner and idle pully, had tension on belt.Moment of disaster, went to rotate engine a couple of times to even out the tension like it says in the book, I positioned myself under the vehicle and removed flywheel locking screw, my not to glamorous assistant thenrotated engine but was struggling but managed a turn, at which point I realised to my horror that the pump pin was still in, nnnnooooo.So what I have at the moment is two bent pushrods, (now replaced all)Issue I have is that now with everything set as the book,(TDC etc) when I rotate the engine by hand ,cylinder one valves are both closed, engine rotates,valves nos 4 and 6 are hitting the pistons.I have taken off the belt again loosened the rocker to allow up wards movement re set tdc and locked flywheel with pin, put the cam shaft on it's mark, locked the fuel pump. put belt back on and tensioned, removed locks and rotated the engine and it still does it, after reading some posts about possibly being 180 deg out, I have reset tdc and locked flywheel (with the belt off) rotated the cam one turn, re set on the marks etc belt back on it still does it.I'm at a loss to know what else could have slipped, with the rocker off, the engine rotates by hand as it should and feels ok no knocking or clunks, i'm trying to sort without taking the head off or the engine out, but I didnt have any issues with the timing when I re built the engine, i;e cam on its mark ,tdc with the flywheel and pump pins etc, so not sure how much credance to put into the 180 degree out stuff I have seen on some posts.