Thread: 300tdi timing flywheel slot not lining up

There are two slots in the flywheel which can confuse things.

You want the 5mm slot, and that should correspond with No. 1 cylinder valves rocking, then everything else should align.

manual or auto gearbox? - "flywheel" timing pin locations are not the same (manual from underneath, auto from the front (of the housing))

I'm aware of the 2 slots ..(manual gearbox) but to get the slot lined up I have to rotate the crank 180 degrees from where the timing mark and pump locking pin should be

Could it be that the flywheel was re fitted 180 degrees out ?

The stud pattern for the flywheel bolts is drilled so the fly wheel can only go on one way with all of the bolts fitted.

To get started, time the crankshaft first.
One way is to pull the number one cylinder glow plug out, insert a stiff piece of wire in the hole, turn the crank over bringing the wire up until you find top dead centre for the No 1 piston and you will see that the timing mark/slot will be visible.

The other way is if you already have the front of the engine dissembled, the key way for the front pulley will be at the 12 o'clock position for number one piston to be at TDC.

Then do your timing belt alignment with the pin in place in the injector pump and then align the cam shaft marks.

A old reverse light switch from a R380 gearbox makes a good lock for keeping the crankshaft in position, it has the correct thread to screw into that inspection hole and the spring loaded plunger slips in place when the mark/slot is aligned, don't try and tighten the front pulley's bolt with it still in place, as it will break the plunger off.
.

Ok so if I time the crank first and line up the slot in the flywheel, the key will be at 6 o'clock ! Not 12 o'clock

I just went outside to the shed and had a look at one of my 300 TDi blocks that still had it's crank and pistons in it and without a head on it, so I could have a good look at it .

The news isn't good for you I'm afraid, the front pulley key is in line with number one crank journal, and when number one piston is at top dead centre ( TDC ) the keyway is at 12 o'clock.

The other end of the crank is the problem then, as there is a dowel near the 12 o'clock position, that is in between two of the flywheel bolts and all of those bolt holes are evenly spaced, so without that dowel being fitted, it is possible that the flywheel can be misplaced inrespect to TDC.

I also had a look at a Ferguson tractor engine I am waiting for a part for and it's crankshaft is the one with the staggered bolt holes, so sorry about any confusion I may have caused with that.
.