200tdi Timing

[Astermagik]

Does anyone know if it is conceivably possible to get the timing wrong on an injector pump of a 200TDi with the pin in?

I removed the timing belt, sent the pump away to be tested and re-assembled with a new belt, but the vehicle won't start. Lots of head scratching later and I'm convinced the pump is pumping (fuel comes out the injectors etc etc) and the engine runs on quick start, so I know the cam / crank timing is right (it definitely never moved while the belt was off anyway). It is as if the pump is 180 degress out or something - everything appears correct, yet it won't start or even try - it's DEAD (I've even tried a very long tow start). Timing marks are all 100% correct - pin in flywheel, pin in injector pump, cam 'dot' spot on arrow.

When the pump was away, could they have refitted the metal plate on the front of the shaft that takes the locking pin incorrectly? Would they have taken it off to fit the pump to the jig? Could they have done anything else to mess the timing? Does the pump have 2 cycles, since it's a 4 stroke and could therefore be 1 whole turn out? (I've tried that and it never worked, so I assume not.) Any ideas fellas? I'm sure it's not something else more obvious - I've been through this for 2 weeks now and I've bled and bled and checked everything else possible.

[Les Henson]

There is a timing 'pip' on the injector pump sprocket as well that lines up with a mark on the timing casing.

Apart from putting the locking pin in to hold the sprocket in the correc t position, you need to set the sprocket in 'neutral' in regard to the shaft it sits on, or it's possible to have the timing set correctly, but actually be one tooth out in either direction. If the sprocket is set on the woodruff key correctly, then you can't put the timing out. Cam and injector pump sprockets are the same size, only the crank sprocket is 50% smaller.

Why did you have the pump over hauled, did you have problems with it? What were these problems?

You say it runs on quickstart? Does it run normally, or is it smokey and lumpy? If so, this is an indication of being one tooth out.

I can't understand how a deisel engine (compression engine) will start on something that's for petrol engines. A long tow start should work though, as even a knackered diesel engine will 'catch-up' on compression and eventually start.

I have Dr Goons motor here on Monday, so I'll check any possibilities that there might be with timing faults on the injector pump.

Les.