300 TDI Wont Start ??

**Jezzaol** · 13th April 2009, 10:48 AM

ok On to it

Originally Posted by Blknight.aus

you have 2 options and one of them youve nearly got done....

first we need to establish the timing order of your pump...

go back through the posts and read the bit that gave the valve timings and make sure that the pump is injecting in the correct sequence even though its 180 degrees out.

if the dribbles occour in the correct 1342 order but are matched up to cylinders 4213 (injecting on each cylinders inlet stroke) you simply need to spin the pump or the cam 180 degrees from normal.

if it turns out to only be 90 degrees out then you must turn the pump

in your case as you have already marked the cam in a 180 out position after double triple and quadrouple checking that your 180 out mark is infact exactly 180 degrees out follow this procedure

Set the crank at #1 tdc
pin the timing pump
remove the belt
turn the crank 90 degrees to mid stroke all the pistons
rotate the cam 180 degrees
turn the crank back 90 degrees to TDC the #1 piston again
reinstall the belt (pin the flywheel if you need to)
double check the timing marks
remove the pin
turn the crank 360 degrees (very carefully if youve goofed the timing you can have the valve meet a piston)
inspect that the cam is now in the correct timing position but the pump is now 180 degrees out
rotate the crank another 360 degrees and the injector pump will be back on the timing pin (which should insert easily) and the cam will again be 180 out.

Re check the injector timing as per previous instructions and ensure that as each paired cylinder comes up that the cylinder that has the rockers free recieves a fuel injection feed from the pump just after the partnered cylinders inlet valve opens

if that works out on all 4 pots then put the glow plugs back in, prep the engine for an emergancy shut down and kick it in the guts.

after it runs (and it will if you get the timing and phasing right) you can either send the pump back to be worked up correctly OR etch mark the timing cover + pump to indicate that the pump is 180 out.

**Blknight.aus** · 13th April 2009, 11:11 AM

bout to cruise PM sent with a phone number.....

call or SMS when you get a result....

**justinc** · 13th April 2009, 11:28 AM

Any further developments Jeremy?
If you can't get hold of Dave, try 0408 995 635.

JC

**Jezzaol** · 13th April 2009, 06:31 PM

For all that are waiting for news ! I am quite happy to say its running like a clock now !

It turns out that the IP was set up 180Deg out thus causing all them problems and 4 days worth of tracking and testing !! I would have never found out without the help of AULRO and especially Dave and Justin !! Thanks guys !

We got it running by swaping the injector lines to suit out of the IP to the correct injectors (temp Only) I will get some more lines made up to suit next week and get the IP adjusted perfectly ! Once we knew exacly how much it was out it was an easy fix the get the fuel to the right injectors at the right time !

She has been taken out on her first test drive and everything mechanicly seems to be spot on !!! phewwwwwwww !!

I seem to have a few little electrical issues that should be resolved easily !! Other than that m back on track for a Kimberly trip next Month !!

PS. I will start another post on the elec issues to se if anyone has any ideas on that !!

CHeers & Thanks
Jeremy

Originally Posted by justinc

Any further developments Jeremy?
JC

**justinc** · 13th April 2009, 06:36 PM

Originally Posted by Jezzaol

For all that are waiting for news ! I am quite happy to say its running like a clock now !

It turns out that the IP was set up 180Deg out thus causing all them problems and 4 days worth of tracking and testing !! I would have never found out without the help of AULRO and especially Dave and Justin !! Thanks guys !

We got it running by swaping the injector lines to suit out of the IP to the correct injectors (temp Only) I will get some more lines made up to suit next week and get the IP adjusted perfectly ! Once we knew exacly how much it was out it was an easy fix the get the fuel to the right injectors at the right time !

She has been taken out on her first test drive and everything mechanicly seems to be spot on !!! phewwwwwwww !!

I seem to have a few little electrical issues that should be resolved easily !! Other than that m back on track for a Kimberly trip next Month !!

PS. I will start another post on the elec issues to se if anyone has any ideas on that !!

CHeers & Thanks
Jeremy

Fantastic Jeremy! Are you still going to get the pump re done? It would be prefferrable as if you ever need an injector line, you will then be able to get an off the shelf item.

I bet you are now intimate with the workings of diesel injection pumps and timing on Tdi's now!

Feels good to overcome a problem like this doesn't it!

Good work!

JC

**dullbird** · 13th April 2009, 06:44 PM

Congrats jezz I have been following this post, admittedly not understanding it very well but following it in the hope you over come your problem

**Jezzaol** · 13th April 2009, 07:28 PM

Yes mate I will, maybe not before I go away in May. But I will get it ll right when I get back.

And yes does feel good to find a problem and then do the required tests to uliminate everything until there is nothing left to doubt !

Originally Posted by justinc

Fantastic Jeremy! Are you still going to get the pump re done? It would be prefferrable as if you ever need an injector line, you will then be able to get an off the shelf item.

I bet you are now intimate with the workings of diesel injection pumps and timing on Tdi's now!

Feels good to overcome a problem like this doesn't it!

Good work!

JC

**MinniTheMoocha** · 13th April 2009, 08:39 PM

It's been a long read tonight and I am so glad it is now working.

This thread has a wealth of information so my hat is off to JC and BlkNight.aus for their diagnosis and investigative work.

By the way how much is it to get an IP rebuilt? When do they normally need to be done?

**Blknight.aus** · 13th April 2009, 11:14 PM

drive in drive out $2K + minimum (if they do everything they are supposed to do)

**MinniTheMoocha** · 14th April 2009, 08:33 AM

Originally Posted by Blknight.aus

drive in drive out $2K + minimum (if they do everything they are supposed to do)

What are the obvious signs that it needs rebuilding? Is it a km mark kind of thing or do you just drive it till it stops?

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