TDC Nightmare

[Krisis]

Hi all,

The van is running but sounds like I have left my tools inside

Notch on fly wheel is lined up

Lock bar fits in the cam

The engine starts fine first turn of the key but sounds as rough as a Badgers Ar*e, I think that somehow that either :-

1/ the timing has slipped

2/ blocked injector or 2

3/ timing is 180 degrees out

4/ blockage in the pump (tested earlier flow was the same on all 4)

All valves where cleaned and working, 4.75 litres of fresh oil, belts fitted and tensioned, battery fully charged, fuel lines flowing nicely, wish I had'nt quit smoking but the JK is doing it for me.

How many times does the fly wheel rotate to the cam ? or do I just keep trying it a rotaion at a time ?

ttfn Kris

[Westy.Club.Joker]

I take it it`s a disel engine? 4.75 litres is too much oil, they are pretty critical on not being overfilled, they hold 4.5 litres with a new filter, so that could be your smoke problem.

Did you have the tool to peg the fuel pump drive sprocket in place when you set the cam and crank timing?

[Krisis]

Mr Westy Club Joker
To be honest the smoke is easy to remedy compared to the percussion thats my engine
The smoke clears quickly but the noise does not abate
TTFN

[Kermit]

Flywheel will turn twice compared to the injector pump, can't see it being 180 out....

Have you got the correct timing mark, its the 'v' on the clutch plate, not the prongs sticking out...

Blocked injector or pump not delivering on one line, crack the union on each injector and see if fuel leaks to check the pump.

I have stuck an injector in a clean jar before to check if the injector is delivering, not very politically correct or a safe working practice but if you are cranking over from the key and don't stick any body parts in the way and after performing a 'full risk assesment' you should be ok .. obviously
your only checking to see if the injector is actually cracking open and not the spray pattern here

The pully's may be lined up (flywheel, cam and pump) but the pump timing may be out .. DTI (Dail test indicator) in the back of the pump to set pump approx 1.0mm lift at TDC ... (much like setting the timing by rotating the distributor on a petrol)

Kerr

[Krisis]

Sorry, quick scanned your message & didnt answer all of it
Pegged & locked the fuel pump with home made peg aka
assorted sockets, extensions & bits
Sorry Kris

[big red bus]

Quick way to check tdc is to remove no1 injector and check piston is at tdc. This will tell you if you have correct timing mark for tdc. Then lock cam and peg pump. Turn engine overby hand, does it turn freely and fell like good compression.

[Krisis]

The timing is SPOT on

But the shells on piston number one have slipped out and crunched a touch before dropping into the oil, found the base and nuts with it

Thats why it sounded like SH*T

I knew I should have checked the torque of the nuts that at hold the pistons onto the crank jobby.

Anyway at least I have got her running and have learn't alot

MOT and then we are off for our weekend jaunts

Thanks for the help and advice.

Kris