200tdi oops!

[SSmith]

have a bit of a sticky situation and would like to ask some advice

theres this mate of mine right.....

after replcaing the timing belt on a 200tdi (defender) somebody :wasntme: forgot to take out the timing pin from the injector pump and reassembled the timing cover....

when the engine was turned over, it all turned pear shaped.

so far diagnosis is a stuffed inner timing cover, some bent pushrods, a stuffed timing belt and one VERY red faced home mechaninc....

im told the fuel pump spins, altho dont know if it is a "normal" spin or not

what other sort of dammage can we expect?

im not there at the moment, but will probably make the treck up to albury to help out with the repair effort wednesday

[kaa45]

Tell Tom I feel for him.......bugger :o
There is an Isuzu motor and LT85 Gearbox for sale in the Market section. ;)

[SSmith]

yeah a situation id rather avoid myself.

he is already talking bout going down that line. worth trying to fix the 200tdi first tho

he got quoted $4000 for a reco injector pump.... Yeah right!

[p38arover]

Oooh! Sounds like those pins need a big ribbon on them like the ones aircraft pitot covers etc., have

Ron

[BigJon]

Oooh! Sounds like those pins need a big ribbon on them like the ones aircraft pitot covers etc., have

Ron

We paint ours bright yellow.

[SSmith]

i use one that is too long for the timing cover to go back on.

still, any idea how much dammage it may have done?

[sclarke]

Valves should not be bent as the valve is 90 deg to the piston. it's a direct hit.

Id get him to replace the pushrods and the cover then do it all again, but remove the timing pin....lol

See if it fires up... if it does then its ok, if not then get the pump replaced...

Thats what i would do, but others might not do the same.....

[justinc]

I have an injector pump sitting in a box that I look at every now and then to remind me TO REMOVE THE TIMING PIN before turning the key...:o

YES, I have broken one a long while back and it still haunts me...It broke the casting out at the front where the pin sits inside, and consequently the front seal and bearing were damaged, rendering the pump U/S.

I would firstly talk to a diesel injection specialist, as a new Bosch VE pump body is only around $400.00. Including labour and seals and assembly set up etc it should top out at about $1100. max. This isn't such a bad thing:eek: as a 200Tdi is getting long in the tooth and could benefit from a pump freshen up anyway....
(Sorry, just trying to be positive:):))
Alternatively, I may have access to a SH unit if you are interested.
JC

[emerald]

I buy up any 200tdi engines I find, most are damaged by guys doing off road stuff and get water sucked in. Last one I got was about 250AUD complete with all accys. The turbo is worth that on its own.

Maybe you could pick up a duff 200tdi engine and swap the parts you need. Rebuilding an injector pump is no big deal, just be very careful and work with clean clean clean tools and work area. I will see if I can dig out a series of pics on rebuilding a Bosch pump. Its not impossible to do, again be careful, take notes and keep clean clean clean with everything.

I have yet to take a pump off a duff engine and find its buggered. Bent conronds and push rods are common with cam belt breakages and hydraulic lock. With your unfortunate engine, it will be cheaper to buy a complete duff engine for parts. Forget rebuilt pumps unless you are really stuck, they are $$$. To make you feel better, be thankful it wasnt a 300tdi pump you had, otherwise you would be heading to the dealer with condom and jar of vaseline in hand :D

[SSmith]

thanks all for your input

i havnt seen the engine as yet so i am going off 2nd hand info
from the sounds of things JC may have it right as far as the injector pump goes. are there any simple tests that you can do to see if the injector pump is ok?

also, what is the likelyhood of anything else being dammaged in the engine, tappet guides, valve heads????

from what im told the engine didnt fire, just a really loud crack when the ignition was turned

i think ron had it right with the ribbon on the timing pin, and attach the key to the other end of the ribbon

[emerald]

If the engine was cranked and then no longer held in starting position on the key when the sound was heard, you could be in for a less expensive repair. You do need to see the pump turned. Only bite the bullet on that one and try it.

Before cranking again, turn the engine slowly by hand and see how it feels. Its safer than cranking the engine live.

A new Bosch pump is 535+VAT sterling in the UK, a service exchange averages 300 sterling. A scrappie might have one, but you gotta be quick. A whole engine from a ratty vehicle always works out cheaper. For export you are not liable to pay VAT.

[SSmith]

thanks again for your input everyone

the defender is back on the road

all up it cost him a couple of seals which replaced because we had it apart rather than because they needed it and a set of bent pushrods

the housing where you insert the timing pin was dammaged, but because the timing pin used was shorter than a normal one it didnt destroy the fuel pump housing, altho how much longer it will last is anybodys guess.

one very lucky bugger, probably out getting it muddy as im typing this ;)