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After the problems I had a couple of weeks ago I decided to change the injector pump on my 200tdi. After changing the pump it still would not start but this was narrowed down to a seized stop solenoid and also a failed lift pump. Both were changed and after a bit of bleeding it start and ran well (on idle in the garage). Today I finally had the time to take it for a good run to check of diesel leaks and that it was running Ok.

It started fine and seems ok when idling, but the noise as soon as you try to drive is amazing. There are no funny or untoward noises, it just sounds like a tdi but in a cave with a microphone!! ie loud thunking. I didnt risk taking it out incase I did any more damage. I have spoken to a couple of friend who also know tdi's but we are at a loss.

Any suggestions?

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Definately sounds like the timing is out, i had these symptoms on my disco after a "garage" changed the timing belt.

I made the mistake of ignoring it.

result - new broken timing belt broken, rocker shaft and some rocker arme broken and 8 bent pushrods.

I'd have it looked at A.S.A.P

Steve

NB; i do my own timing belts now!

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How disappointing is that! I was reading the post thinking 'I know the answer' and once again have been beaten to it!

Happens to me all the time! Ralph is the main culprit! :D

In answer to the thread. What they^^^^^said!

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Thanks all, going to check it tonight.

Had discounted the timing as it was locked up with "proper" timing pins when the pump was changed.

However fingers crossed that is the problem.

Could the belt have slipped and how do I adjust the timing?

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OK so it does not seem to be timing. The pins popped straight in with no problems.

Could these symptoms be caused by contaminated fuel? There is a possibility that some petrol has been put into the jerry can that was used to fill the tank. Could these symptoms be caused by this?

Running out of ideas!!

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If you replaced the pump, isnt it possible to advance or retard it by pivoting it on the bolts that connect it to the timing cover? I can never figure out the correct procedure for changing pumps as they should be locked when removed from the donor engine so they are int he correct position when attached to the recipient, but i'm sure there is some adjustment possible after fitting (a little like twiting the distributor on a petrol engine i suppose). May be completely wron on this, but someone who knows will be along to confirm or disregard what i say! :)

Other than that, i wonder if an injector may be at fault and knocking? or if the the volume screw has been fiddled with on the pump - but this would result in smoke rather than knocking.

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If you replaced the pump, isnt it possible to advance or retard it by pivoting it on the bolts that connect it to the timing cover? I can never figure out the correct procedure for changing pumps as they should be locked when removed from the donor engine so they are int he correct position when attached to the recipient, but i'm sure there is some adjustment possible after fitting (a little like twiting the distributor on a petrol engine i suppose). May be completely wron on this, but someone who knows will be along to confirm or disregard what i say! :)

Other than that, i wonder if an injector may be at fault and knocking? or if the the volume screw has been fiddled with on the pump - but this would result in smoke rather than knocking.

Not sure but as far as I can remember 200tdi pump bolt holes are not sloted, however the pump timing could well still be wrong. If the previous owner of the pump has undone the centeral nut in error as opposed to the three 8mm bolts then the timing will have moved (no woodruf key they rely on the tapper). Unfortuatly this can only be checked with a Dial test indicator and a special adaptor. I would just take the pump off and take it to a diesel fuel sytem specialist, last time they charged me £20 to check and adust it. :)

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If you had enough petrol in there to make a difference to the running, it would stop after a while due to vapour locks in the injectors.

Personally, I've always set the timing on 2/300 TDi engines by ear. Although that's mostly because I have used 'interesting' fuels that require slightly different timing to diesel - therefore the pins are in the wrong place.

As you've fitted a 2nd hand pump, it is possible that something is amiss there. For the sake of £20 I'd take it in to be looked at.

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Thanks for all the suggestions - finally got to the bottom of the problem.

Looks like a batch of dodgy diesel - during investigations was aware of a strange smell from the fuel tank so rigged up a temp tank (5litre can) straight into lift pump and tried it on clean diesel. Hey presto, ran sweet as a nut. Drained the tank, refilled with new diesel and a quick spin suggests everything is back to (better than) normal.

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