Injector Timing

[fastrack1966]

Last stages of the diesel head saga and I'm unhappy with the injector gear timing. Found the lockbolt on front of injector, got the B mark as close as I can see to the mark on the cover. Not a good view unless you go at the offside wing with a chainsaw.......
I have the same problem as another poster in that with the camgear and the injector gear set dead on, the timing belt going from one to tother is half a tooth out. Slackening it by half a tooth to get it sitting snug leaves far too much slack. Pulling it towards the injector gear and it won't stretch!
Obviously to move one of the gears to make the thing fit will upset the timing. Annoying that I got the same belt on new in July easily and drove off. Any ideas why this half tooth discrepancy?

BrianJ

[G Force]

Hello mate. What you need to do is lock the crankshaft with the locking pin, lock the camshaft with the locking pin, then set the injector pump initial timing by lining up the gear with the mark on the cover, then to fit the belt you need to undo the bolts in the camshaft gear vernier to get the correct belt run and then set the belt tension. It is sometimes necessary to loosen the idler pulley to get the belt around the crank pulley to injector pump pulley then re-tighten it before you set the belt tension of course. Once you have set the belt tension you need to rotate the engine twice clockwise by hand then re-check the belt tension, if it is not correct you need to repeat the whole procedure. When you are happy with the belt tension you need to set the injector pump timing with a DTI gauge but a special tool is needed to attach the gauge.

Cheers Gary.
:) :)

[fastrack1966]

Thanks Gary, the camshaft gear vernier looks like the answer to sloppy belts, but what is it?!

BrianJ

[G Force]

Hi Brian

The vernier camshaft pulley allows the gear position to be moved independently of the camshaft. In the case of the Mdi it is there to maintane accurate valve timing when adjusting belt tension.

Cheers Gary;)

[fastrack1966]

Sorry Gary, where is it? I've had the cam pulley off often, so I hope I know where to look. Is it in Haynes, I've not seen it

BrianJ

[fastrack1966]

Maybe I should have specified its a 93 2.0 turbodiesel Gary

BrianJ

[G Force]

Brian.

It is the cam pulley itself. Your pulley should have one large bolt in the centre holding it to the camshaft, then four bolts around that. un-doing these four bolts a little allows the gear to rotate slightly about its centre hub.

Cheers Gary:)

[fastrack1966]

Thanks Gary, I always thought a vernier was a ruler with a slidey thing on it! Hope I'll give it a whirl tomorrow,

BrianJ

[G Force]

Originally posted by fastrack1966
Thanks Gary, I always thought a vernier was a ruler with a slidey thing on it! Hope I'll give it a whirl tomorrow,

BrianJ


Yeh Brian thats a vernier gauge or vernier caliper. :laugh: :laugh:

Cheers Good luck:)

[F 447]

[i]Originally posted by G Force. When you are happy with the belt tension you need to set the injector pump timing with a DTI gauge but a special tool is needed to attach the gauge.
Cheers Gary.
Hello Guys, As I still have to fine tune my injector timing, can anybody tell me where to get this DTI and special tool to do this job accurately? I could only find one kit covering several cars for mega money. There must be another way. :confused:

[fastrack1966]

Oh Well got the timing right, still no joy. Looking for fuel leaks is obvious, I hope, but if theres an air leak where will I find it guys?

In another thread some may recall my turbo stiffened up whilst off the car. I am sure it spun when refitted - but will the car start if the turbo is a bit stiff still? I dread removing that thing again,

BrianJ

[E_T_V]

With a siezed turbo it'll most likely run but not run well and it'll smoke like a trooper. It'll basically have the same effect as stuffing 3/4's of a potato up the exhaust :D

I'd have a go at bleeding the fuel system again if you can bear to do so. From fuel pump to injector pump then the injectors themselves.

Also check the fuel filter hasn't got water in it and the tank line hasn't sprug a leak..

I'll be cheekey too and remind you to check there is some fuel in the tank too :D :p

[G Force]

Also check that the fuel cut off switch on injector pump (check your manual to identify the correct one) has 12v going to it and it is operating when the ignition switched on. The supply is fused, so check those first if you find you have a problem.;)

[fastrack1966]

Thanks everyone. More bleeding next. Since there is fuel squirting when I slacken the bolts atop the 4 injectors can I assume the cutoff switch is OK or shall I identify it and check anyway?

BrianJ

[fastrack1966]

Still a bit confused over air in fuel:
I had a local mechanic call by, all he did was slacken the nuts atop the injectors and he saw fuel squirting out which was good enough for him. But when I previously UNDID each pipe one by one from each injector and squirted fuel into a plactic cup nbr one had lots of tiny air bubbles. Are tiny bubbles concerning, or are we only looking for gurgling pockets?!
Does turning the engine with an injector pipe completely undone at the injector like I did allow yet more air into the system?

BrianJ

[G Force]

If you get a consistant ammount of fuel at each injector union then you can assume cut off switch is ok. A little foaming of the fuel as it leaks past the union as you bleed is ok it is just the nature of diesel.:)

[fastrack1966]

I wouldnt say it was foaming, its tiny bubbles in the fuel that we're not supposed to see in brake fluid, but if its OK in diesel then I'll assume the fuel supply is OK?

BrianJ

[E_T_V]

Any bubbles in diesel can cause problems, try to get rid of the tiny bubbles as the injector pump only delivers a minute amount of diesel per cycle.