major smoke, engine half dead :(

[fender1234]

provided you haven't undone the bigger central nut, & only removed the timing gear to remove the FIP from the timing case,when you build the engine up, refit the FIP & it's timing gear then turn it so the timing pin [aka 9.5mm drill shank] fits, final timing can then be done as per the workshop manual.

ah thank god for that, thanks alot Western

[western]

got to do it myself shortly, in the process of stripping the timing case of to extract some sheared bolts, can't get my drill in with the case fitted to the block, so will be doing the timing belt while I've got the chance, then I don't have to worry about it for another 55,000miles

[fender1234]

I've never had the guts to tackle a cambelt change, now Ive found myself stripping the engine to peices, quite daunting when u see your whole engine in peices, knowing that i've got to put it back together again

[gaz0203]

can i see the fuel pump gear and central boss on the floor in your pic?? does this mean you have undonr the large central nut and not the 3 around the boss? if so id take the pump and boss to your local diesel specialist get them to refit it and time it correctly

[western]

can i see the fuel pump gear and central boss on the floor in your pic?? does this mean you have undonr the large central nut and not the 3 around the boss? if so id take the pump and boss to your local diesel specialist get them to refit it and time it correctly

I can see the FIP timing gear but can't see the FIP itself in that photo.

[fender1234]

That's just the gear, I havnt undone the big nut.

[reb78]

I think the confusion is that there is one big nut on the front of the FIP that holds that gear on isnt there? Or do you remove the plate with the three bolts and the gear slips off over the nut?

[western]

I think the confusion is that there is one big nut on the front of the FIP that holds that gear on isnt there? Or do you remove the plate with the three bolts and the gear slips off over the nut?

always remove the gear & it's 3 bolts/plate, if the large centre nut is undone, it can disconnect parts inside the FIP which will then need a rebuild/resetting.

[fender1234]

I am going to send off the ip and injectors to be tested to make sure they are all good, can anyone recommend anywhere, preferbly down south.

thanks

[gaz0203]

all that happens if you remove the large centre nut is that the gear comes off the pump shaft, but theres no keyway to put it back correctly!!!!!!!!!!! im speaking from experience. not something ill ever do again in a hurry!!! in the end i had to look closely at the pump shaft, there is a keyway groove in the gear and it left a mark on the shaft, so i marked it and fitted it back there. unfortunately it would not run so had to slacken the 3 pump bolts and insert the timing pin, then move the engine on slightly by turning the crank pulley. bit by bit until it started and ran. no idea where the timing is exactly but it dont half fly!!!!! in aperfect world id have removed the pump and got our local diesel specialst to put it back on in the right place. this a 2 minute job if your in the know!!!!!

[fender1234]

Thought id finish this off with a few pics, engine is all in and running like a dream, so far . The work have dones is, 020 overbore and hone, new pistons and rings, crank polished and new main and big end bearings and thrust washers, new cam bearings line reamed by Turners, core plugs, new cambelt, tensioners etc and all oil seals and gaskets.

[markyboy]

That looks fantastic.

You should feel proud of yourself, and rightly so.

Well done.

Mark.

[fender1234]

thanks ive surprised myself a bit as ive never tackled anything major like this before