200tdi Late Flywheel Pin Versus Fuel Injector pump Pin Location

[Lionelgee]

Hello All,

Can flywheels be positioned incorrectly so that slots that locking pins fit into can be out of alignment? A photo of the locking pin for the flywheel is attached below. I am replacing the timing belt.


I have been watching a couple of Trailerfitter's Toolbox Videos and they mention that the first thing you do is find the correct slot in the flywheel to fit the timing pin from the timing kit. The wading plug the pin goes in is one located at the back of the engine closest to the gearbox. Because the 200tdi is from a Defender it has no static idler. The Trailerfitter video must feature a 200tdi from a Discovery as it has an adjustable idler and a static idler. I have to say that it does breed a bit of confusion when I look at the video and then go work on the Defender's motor!

From there you make adjustments so that the special diesel injector pump pin fits into and out of the fuel injector pump easily to lock and unlock it. Also that the arrow on the back timing cover casing and the dot on the camshaft pulley align and the woodruff key on the crankshaft lines up with the arrow/web of the back timing cover casing.

I have been under the Defender multiple times and also frequently turned the motor over. I cannot align the flywheel locking pin so that the three markers at the front of the engine: injector pump pin, dot and arrow on camshaft or woodruff key and mark line up.

The Trailerfitter videos mention how there are two different slots that the flywheel locking pin can fit into. One is correct and the other is not. I have tried both these slots and neither are positioned within cooee of the position of the woodruff key on the crankshaft and the marker on the back timing cover casing.

I have positioned the fuel injector pump pin so it fits easily. Also, the camshaft pulley dot and the arrow line up perfectly. Plus the woodruff key o the crankshaft lines up with its marker. Yet going off the flywheel pin the closet I can get the woodruff key to the casing marker is having the key at around the three o'clock position.

What is more important mechanically - getting the flywheel slot/pin to line up?
Or having the three pulleys: fuel injector pump locking pin; camshaft pulley dot and the arrow; plus the crankshaft woodruff key and the marker on the casing all align?

Apparently, I cannot have all factors lining up with the flywheel slot/pin. Because I can easily line up the three pulleys and their respective markers I am inclined to just ignore the flywheel slot/locking pin. Hopefully this will not be at the motor's and my peril - fingers crossed.

The videos and the timing of the where the flywheel slot/pin are mentioned were accessed 6th November 2021 from, Land Rover 200tdi Engine Fitting the Timing Belt - YouTube (https://www.youtube.com/watch?v=_s_Sw8oOTBw) at the 4:11 minute mark and Land Rover 200tdi Timing Belt -From Broken Belt to Retiming the Engine - YouTube (https://www.youtube.com/watch?v=VPzC_Dr6KzU&t=1324s) at the 11:33 minute mark. The photo showing the flywheel slot/pin is sourced from the Trailerfitter videos.

Kind regards
Lionel

[Lionelgee]

Hello All,

I found a Britannica Restorations video on YouTube where the flywheel pin is not used. Instead, while the head is off, he has a dial gauge fitted to Number 1 piston to find top dead centre (TDC) – shown at the 17:13 minute mark. Accessed 7th November 2021 from, 300 Tdi rebuild. Problems and timing belt fitting part 8 - YouTube (https://www.youtube.com/watch?v=nvZ5ftLdyIs)

I am not going to take the head off just so I can use a dial gauge to locate TDC. Instead, I will take the glow plug out for Number 1 piston and rig up a stud which fits the glow plug thread and drill the hole down the centre of the stud. The top of the stud will be fitted to the pipe out of a vacuum gauge which has the Schrader valve taken out. As per Eric the Car Guy’s YouTube video How To Find TDC The 'Easy' Way. Accessed 7th November 2021 from, How To Find TDC The 'Easy' Way -EricTheCarGuy - YouTube (https://www.youtube.com/watch?v=u2sA-q7_FtQ). This will allow me to confirm that the markings on the fuel injector pump pin, the dot on the camshaft pulley and the mark on the timing cover base; plus the crankshaft woodruff key and its marker are all actually lining up on the compression stroke.

I used this technique to find TDC on a Holden 202 motor when I went to fit an electronic distributor kit. Eric the Car Guy’s tip worked and the engine fired up straight away. Hopefully this technique to find TDC will successfully transfer across to the 200tdi – fingers crossed. This will be a "tomorrow" job because its Sunday and the nut and bolt places are all closed in town.

Kind regards
Lionel

[Blknight.aus]

your flywheel may be the incorrect one.

Do a bold adjust off of #4 cylinder by removing the glow plug (or an injector in which case you can do #1 you can also do #1 if you dont have the AC pump in place) wind the engine over until the marker says #1/4 is TDC, put a small rod in the hole and touch the piston top, then crank the engine over very slowly until the rod stops moving upwards (if it starts moving downwards immediately stop remove the rod, roll the engine over about 340 degrees) then redo the trick with the rod.

which ever mark lines up for the crank when the rod is topped out is your TDC marker.

[Lionelgee]

your flywheel may be the incorrect one.

Do a bold adjust off of #4 cylinder by removing the glow plug (or an injector in which case you can do #1 you can also do #1 if you dont have the AC pump in place) wind the engine over until the marker says #1/4 is TDC, put a small rod in the hole and touch the piston top, then crank the engine over very slowly until the rod stops moving upwards (if it starts moving downwards immediately stop remove the rod, roll the engine over about 340 degrees) then redo the trick with the rod.

which ever mark lines up for the crank when the rod is topped out is your TDC marker.

Hello Dave,

Thank you for the reply. As this is my first go working on a 200tdi I did not know whether the glow plug hole allowed access to the top of a piston. The Defender does not have air conditioning so Number 1 cylinder is easily accessible.

I had another go at using the fly wheel pin and fly wheel slots today and it came up with the same results as yesterday. The fly wheel slots are way out of alignment to the crankshaft woodruff key. Despite this when the woodruff key is aligned to the marker on the back timing cover the injector pump pin and the camshaft dot and cover markers fully align. Now I just have to make sure this is happening at TDC.

It's dark outside now, so it will be a tomorrow job.

Thank you again for the detailed reply.

Kind regards
Lionel

[Blknight.aus]

if the engine was running and the cam side markings line up, use them and ignore the flywheel. but be careful its possible to miss align by a tooth on the crank gear because of where the marker is and the lead in angle on the belt.

if the old belt is still on paint pen mark the belt and all pullies then transfer the marks to the new belt.

Be wary that due to stretch the belts may not be the same length exactly so double check with tooth counts.

[Lionelgee]

if the engine was running and the cam side markings line up, use them and ignore the flywheel. but be careful its possible to miss align by a tooth on the crank gear because of where the marker is and the lead in angle on the belt.

if the old belt is still on paint pen mark the belt and all pullies then transfer the marks to the new belt.

Be wary that due to stretch the belts may not be the same length exactly so double check with tooth counts.

Hello Dave,

I took the timing belt off about a year ago. The car was running and driving when I bought it. There was an issue with the fuel injector pump leaking badly so I took it off and got an exchange rebuilt unit. Being a farm vehicle the front mudguards were beaten up so I took them off and I got the radiator and intercooler off and tested. The previous owner could not remember when the timing belt had been replaced. So, I took advantage of all the available space to replace the timing belt and related bits.

Then various domestic building projects happened - plus some study, and pages rapidly flipped over the calendar before I could get back to working on the engine again. Luckily, I bagged, tagged and labelled everything.

Kind regards
Lionel