Club 80-90 Forums

Hi All,

Some back ground, I pulled the motor and gearbox to solve a clutch problem and fit an input shaft seal and a stack load of little jobs. While it was out I decided to do a cambelt as it looked well past its best despite being told it'd been done recently. The tensioner pulled had play in it as well and was a little hard to start.

Anyway, did cambelt. Found TDC, locked camshaft with correct tool and feeler gauges, locked pump. Changed belt. Turned over several times all good. Fitted timing adapter and dial gauge at TDC wound anti clockwise until it stopped dropping, reset to 0. Clockwise back to TDC and adjusted as close to 1mm as possible.

I found that after winding over a few times it would either under or over read by 1 or 2 hundredths. I think I eventually settled for an average of about 0.98 lift at TDC.

Prefilled the diesel filter topped up pump as some fuel escaped when timing it.

It started on the second attempt and idled on 3 quite lumpy, pushing the throttle has no effect at all not even a little.

Ran out of light to do anything else but I'm thinking I've either cocked up the valve/pump timing or I have an air lock problem.

Couple of notes,

The pump lock was hard to get in before I took anything off, presumably cam timing was a bit out. Its all bang on now.
I accidentley removed the Full Load Setting Screw (amature mistake but it was late and I was knackered.) I put it back exactly where it came from.... See pic below;



Any suggestions?

As a side note I found this, may come in handy for Diesel owners;
http://issuu.com/rswords/docs/bosch_ve_manual

After some research I have some possibilities, found this thread from the Brickyard:

http://www.brick-yard.co.uk/forum/is-my ... 72532.html

Would timing the pump 180 degrees out cause this problem?

The thread suggested that control collar (rests against the Full Load Screw) may be stuck, perhaps disturbed from me removing it?

Any thoughts appreciated.

Did you remove anything else[fuel feed n return?]

I can tell you that (on my pump at least) the spline when at tdc and with the pulley removed points left and slightly down - hope that helps on the 180 out or not question

dave friday wrote:Did you remove anything else[fuel feed n return?]

Yes the whole engine was out so feed and return were removed and filter has been changed.

Smcknighty wrote:I can tell you that (on my pump at least) the spline when at tdc and with the pulley removed points left and slightly down - hope that helps on the 180 out or not question

Cool thanks.

Well I did get it running;

Went back through the timing work that I had done, and made a small adjustment to the pump but only a few 100ths of a mm, pump timing now bang on 1mm. Cam timing fine.

For the 180 degree out thing, I cracked off No.1 injector fuel line and turned the enine over TDC by hand and got a pulse of fuel from the pipe at TDC. So the pump is injecting on the right cycle.

Went through all the fuel connections again and found a few problems with some of the new copper washers I'd been using. Tightened and rechecked.

Started and bled the injectors by loosening the lines one by one. Plenty of air in the pump.

Running much better but still no throttle.

Engine off removed Full Load Setting screw and used a screwdriver to operate the lever inside the pump carefully to ensire its free and smooth. Put the screw back in and started, better again and some throttle. Now gave the screw a turn in, ended up with the screw turned in +1 turn from where I had put it back to and engines running very nicely (not driven). Certainly running much smoother than before.

I could'nt test drive it as the exhaust had mostly cracked through at the Turbo end, some **** has welded the nuts holding the exhaust on to the exhaust flange. So back under again tonight to drain the oil I have just put in and get the turbo off.....

I just wants me to work a bit harder before I can use it

Silly question here but you have checked that you have the correct union on the feed and return? the return is much smaller bore allowing pressure to build in the pump, if they are interchanged it will cause those symptoms.

Regarding the pump being 'out by 180 deg' ... not sure this is actually possible. If the hole in the sprocket is aligned with the hole in the steel cover behind, then the pump is correctly positioned (bar adjusting the lift pump). There isn't a way to get it wrong, is there? I've timed up a few of these engines, and never experienced one to be 180 deg out.

Check that you havent swapped the" in" fuel feed bolt for the "out"fuel back to the tank bolt [the out bolt has a smaller hole in the side of it]

You didn't take the throttle lever off for any reason did you ?

Thanks for your replies, I have it ticking over nicely now, reponsive and no so much smoke, just hope its all good when I drive it.

I have not had the throttle lever off and left the hoses connected to the unions and just unbolted them so no way to mix the connections up. Re timing I think I was just doubting myself and the work I had done so went back through it all.

As a side note I had a friend take a T4 into a commecial van garage near me and they managed to "cock" up the cam/injection timing and then started to diagnose the glow plugs as the issue, so I thought it would be prudent to check mine again.

dekhelia wrote:Regarding the pump being 'out by 180 deg' ... not sure this is actually possible. If the hole in the sprocket is aligned with the hole in the steel cover behind, then the pump is correctly positioned (bar adjusting the lift pump). There isn't a way to get it wrong, is there? I've timed up a few of these engines, and never experienced one to be 180 deg out.

You are quite right, after some food and sleep.... Its possible to time the pump on the wrong compression cycle but not 180 degree out if the pump is locked correctly!