Swilli Posted November 21, 2019 Share Posted November 21, 2019 Hi im having problems timing injector pump setting pump as manuals tdc on flywheel slacken 3 pump plate bolts adjust pump set pin in slot tighten 3 bolts then turn engine over by hand and hey presto pump pin does not fit .with everything tighti can sill move pump witb socket have swapped pump about six months ago timing belt changed 30,000 miles ago Quote Link to comment Share on other sites More sharing options...
Snagger Posted November 22, 2019 Share Posted November 22, 2019 You should be moving the sprocket on the pump, not the pump on the casing. It sounds like you’re trying the method for the 12 and 19J engines, not the Tdi. Quote Link to comment Share on other sites More sharing options...
reb78 Posted November 23, 2019 Share Posted November 23, 2019 Are you rotating the crank twice before you try to put the timing to back into the injection pump? Quote Link to comment Share on other sites More sharing options...
Swilli Posted November 23, 2019 Author Share Posted November 23, 2019 Thanks for your thoughts on this my adjusting of the pump is right. 2:1 ratio etc i have since found what i think is small piece of timing belt showing through timing casing drain bung hole , the inj pump feels as though its under tension when trying to adjust so just in process of removing timing casing in between the rain clouds I'll let you know the outcome Quote Link to comment Share on other sites More sharing options...
Swilli Posted November 24, 2019 Author Share Posted November 24, 2019 Timing casing is off, set up timing belt to check only to find the crank gear has had its keyway widened by both woodruff keys allowing many degrees of unwanted movement ,both woodruff keys were close to shearing , timing belt had caught its edge on the tensioner ridge and stripped about 3mm off the edge leaving shredded bits throughout,had a pushrod shear/snap about a month ago but that got replaced with no visible problems or running issues until starting it up a few days ago and it ran ,sounded and smoked like a single pot lister ! anyway new belt kit, crank gear and keys , tthanks to all for viewing and replies Quote Link to comment Share on other sites More sharing options...
reb78 Posted November 25, 2019 Share Posted November 25, 2019 At least you have found the problem! What does the crank shaft look like - is that damaged or ok? I put a small smear of loctite on the crank, particularly around the woodruff keys to avoid this movement and keep everything nice and tight. It does make removal a little more difficult - i.e. definitely need to use a puller, but I think its worth it to mitigate the risk of this problem somewhat. Quote Link to comment Share on other sites More sharing options...
Swilli Posted November 26, 2019 Author Share Posted November 26, 2019 Well i seem to have got away without any keyway damage one of the two keys is being a bugger coming out ,crank gear badly worn , new parts on order with Paddocks lots of rain slowing me down just found old waterproofs ,this engine has just clocked up 200,000 I've had it nearly nine years. I had woodruff key problems with my old rrc 200tdi then it chewed into the crank ,i welded keyway but never felt i could trust it on long journeys although it ran ok and with a rotting front door pillar caused by sunroof drains blocked it became a donor with about 170,000 miles thanks for the suggestion of loctite not sure if it was used when a friend did the belt last but the crank damper wouldn't have come off without special tool ,anyway ill try to get a bit more done today Quote Link to comment Share on other sites More sharing options...
Ex Member Posted November 26, 2019 Share Posted November 26, 2019 Paddocks? That won't improve things! Quote Link to comment Share on other sites More sharing options...
Swilli Posted November 27, 2019 Author Share Posted November 27, 2019 I can't disagree ! ordered dayco belt kit ,supposed to be OEM ,but a wasn't expecting Britpart tensioner etc will use them as i assume the fitted parts have already been changed Quote Link to comment Share on other sites More sharing options...
reb78 Posted November 27, 2019 Share Posted November 27, 2019 LRDirect and Britcar are your best choices for parts in my opinion. Both have a wide choice of options and good customer service. Britcar is just beating LRDirect on prices for a few identical items at the moment. Quote Link to comment Share on other sites More sharing options...
Swilli Posted November 30, 2019 Author Share Posted November 30, 2019 All up and running , now for the exhaust manifold gasket i notice is leaking then drive it to the next problem !! Quote Link to comment Share on other sites More sharing options...
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