300tdi timing issues

**philandmickey** · 31st January 2019, 07:19 PM

Hi

I have just replaced the injector pump on my 96 Defender 130.

The original was leaking so I bought a second hand one, put all new seals in it and then had an injection specilist test, recalibrate and fit the drive hub as it did not come with one.
I now can't get the car started, it seems to have pleanty of diesel at the injectors when I slack off the pipe nuts a turn.

I placed the timing pin in up through the bell housing to the flywheel and inserted the pin into the front of the pump and did the swap over.

I have found there are 2 slots on the flywheel 1 is approx 5mm wide and the other approx 8mm I believe I may have inserted the pin in the 8mm slot, putting the timing out a fair bit.

If I now try to time it using the 5mm slot I can not put the pin in the front of the pump as the hole in the pully for it to slot into is approx 180 degrees out from where it should be.

I would say the pully and belt have been timed wrong but the car was running ok (a bit smokey but ok) before I swapped over the pumps.

I would apreciate any thoughts / ideas / advice anyone can offer.

Cheers
Phil

**jboot51** · 31st January 2019, 08:35 PM

another full rotation of the crank should bring the pump into alignment. You would currently be at the top of the exhaust stroke.

**philandmickey** · 31st January 2019, 08:51 PM

Thank you
Yes I am a prize plonker, I have just been out in the dark rotating the engine once more and hay presto it all lines up! I am so embarresed.
The engine will still not start but at least I now know it is times correctly.

**AK83** · 31st January 2019, 10:52 PM

Originally Posted by philandmickey

Thank you
Yes I am a prize plonker, I have just been out in the dark rotating the engine once more and hay presto it all lines up! I am so embarresed.
The engine will still not start but at least I now know it is times correctly.

This is going to sound bleedingly obvious .. but the solenoid wire has been reconnected properly again!

**philandmickey** · 1st February 2019, 05:13 AM

Hi
Yes stop solanoid connected, I have also swapped it over with the original pump in case it was faulty.

**jboot51** · 1st February 2019, 06:45 AM

When you removed the pump, did you secure the the pump pulley to the timing case using the special tool?.
If not, the belt may have jumped a tooth putting the crank/ cam timing out.
You really should remove the front cover and check timing.

If you remove the rocker cover and watch #1 in/ex valves as you rotate the crank, the rockers should go relaxed as the crank reaches tdc and fuel should dribble out of the injector union.

**Red90** · 1st February 2019, 06:51 AM

Or... the "specialist" put the hub on in the wrong location. Try and see if #1 squirts right as the hub passes the slot to verify it was set for the right cylinder. If that look good then check the timing with a dial gauge.

**philandmickey** · 1st February 2019, 11:35 PM

Hi
Yes all correct timing tools used.

I eventually had to give in and refit the original pump.
The car started instantly, so the problem definitely lies with the new pump, I am pretty sure the hub has been fitted incorrectly,

So the pump has been returned to the specialist along with printed instructions on how to time it and fit the hub!
Hopefully this will sort it.

Thank you everyone for your advice I will keep you posted of how I go with it.
Phil

**justinc** · 2nd February 2019, 05:08 AM

He has mistimed it, local market mech pump vs overseas strict emissions electronic pump. Not uncommon as it has happened to us. Apparently the firing order for a fly by wire 300tdi pump reverses 2 of the cylinders, and as such their pipework is totally different from the pump to the injectors compared to the non electronic pumps. At least that was the reason we were given for the mix up..

**Blknight.aus** · 2nd February 2019, 03:27 PM

Originally Posted by justinc

He has mistimed it, local market mech pump vs overseas strict emissions electronic pump. Not uncommon as it has happened to us. Apparently the firing order for a fly by wire 300tdi pump reverses 2 of the cylinders, and as such their pipework is totally different from the pump to the injectors compared to the non electronic pumps. At least that was the reason we were given for the mix up..

supportable, have seen this twice when you buy fly by wire injector lines in place of ours....... trying to get the right pipe from the right injector to the right valve on the IP needs a touch of massaging.

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