300 TDI Wont Start ??

damn ring ins, I havent even had coffee yet.....

(but sound advice anyway)

cmon man, what gives, youve had time to put the thanks on the posts from this morning........


(I gotta be on the road in about 3 hours.)

Goodmorning.

Here is a closer pic of the cam gear, also a pic of the New Injection pump I fitted.

I'm not sure where the slack in the belt was ? I thought that if all the marks lined up I was OK?

Im not sure what your saying about the pump pully, He told it it was locked into position set up ready to go, all I had to do was fit it and slide in the locking pin and set the rest up as per normal timing and fit locking plate thingy.

What is my Fix ? How do I do it and make sure it right ? you told me my timing is WAY out ?
Cheers
Jeremy

Quote:

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Originally Posted by Blknight.aus

from that picture (the oblique angle makes it hard) It looks like the cam timing is one tooth out.

when you let the tensioner take up where was the slack on the belt?

and I know what the stupid thing is that we've missed.

the timing is adjusted by turning the timing gear on the injector pump boss. That pully has to come off to rebuild the pump. When your mate did the rebuild where did he set the pully on the injector pump? you cant put the pully on in totally the wrong position (the bolts are off set so you cant get all 3 in if you do) but you can advance it or retard it so far that it wont start easily/at all. (pump advance and retard is set by the slotted bolt holes)

If you have the slack in the wrong position when you let the tensioner pull up it can also pull the timing out, Combine the worst of the belt adjusting and pulling the timing into advance/retard and the pump being set near maximum advance/retard and your not going to get a start.

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I know I know !!.......... Its early over here !! and it takes a bit to upload the pics ;)
now I'm waiting on you ;);) you only have about 2.5 hours left to get me on track !!! :angel: good luck!

Quote:

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Originally Posted by Blknight.aus

cmon man, what gives, youve had time to put the thanks on the posts from this morning........


(I gotta be on the road in about 3 hours.)

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OK back to uber basics...

go out there, remove all the glow plugs, crack injector line #1 at the injector set the engine up ready to start, if need be wind the engine over a few times to make sure that the fuel system is primed.

wind the engine to TDC on pot 1 and insert a long skinny shanked phillips head screwdriver into the #1 glow plug hole and it should sit on the piston crown, slowly wind the engine forwards as soon as you start turning the crank if you were at TDC then the screw driver should drop in with the motion of the piston (this is to ensure that your keway hasnt been repaired and is off) Remove the screwdriver, clean up the #1 injector union.

roll the engine over slowly as soon as you see diesel coming from the +1 injector union identify the position of the valves on cylinders 1+4, (you should be shy of TDC at this point) then roll the engine over just a little more to establish what valves are doing what. (the inlet rocker on #4 should have just been starting to move before the injector line dribbled)

at the point that injection commences (the diesel drips) you should have both rockers on pot 1 loose an the rockers on pot 4 tight. If its anything else write down the position of all the valves and post it up.

why is there 2 timing marks 180 apart on your cam gear?

(please tell me that one is a paint pen mark that youve put on)

Yes the second one is just a paint pen:angel: got a bit line marking happy!

Quote:

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Originally Posted by Blknight.aus

why is there 2 timing marks 180 apart on your cam gear?

(please tell me that one is a paint pen mark that youve put on)

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Morning all,

Yes Jeremy Dave has it all in hand, we have now established that your pump and timing is fine, but I still reckon the injection is happening at the wrong time, IE the pipes are still mixed up OR the pump is assembled incorrectly. As I mentioned in an earlier post the EDC pumps are totally different in their pipe orientation, and I have already had 1 diesel injection specialist assemble one up incorrectly...not realising that the non EDC VE pumps are different.

You can refit the timing cover now and go through Daves explanations on checking when the fuel is ACTUALLY injecting:)

JC

ok so what are those valves and injectors doing in relation to each other now?

and an edit for JC.....

so when you say timing you dont differentiate between the phasing (injection order/on what stroke it happens which Ive also refered to as the coarse timing) and the fine timing (at exactly what degree) on a diesel setup?


and an edit for Jezz. Leave the timing cover off, if the pump is assembled with the firing order exactly out of phase or in reverse you need to slip the timing of the cam or the pump to sort it. (and all can be forgiven with the TDI with either injector pump if youve got the patients to work through the cam sequence and the pump sequence and about 80% of the time you dont need to bend the pipes if they all make it to the unions in the right firing order)

OK, when the diesel squirts the cam puley is exactly 180 Deg out (see Pic) at this stage the inlet valve on #1 opens just as diesel starts to drip from #1 injector union.

At this same place #4 inlet valve is closed, #3 inlet valve is starting to close and #2 was closed

Next ? Do you need me to tell ou where the valves are at TDC ?

CHeers
Jeremy