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diesel pump setup/referance?

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Vanorak
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    Posted: 12 Mar 11 at 02:13
chaps had some issues with my 1.9 1y motor which ended up with my headgasket blowing
 
anyway fitted that lot but...................what i did before stripping the head off etc was a bit dumb of me, pressure of it being my daily rushing a job when i should have, what i did was line up my marks on my timing belt & engine block but forgot that the crank pulley should be at TDC (dumb bastard)
anyhoo, got that all sorted but i think my diesel pump is now out of sync if that makes sence?????
 
my engine wont now fire up
 
now the diesel pump, should that be set in a specific postion? i know you can fiddle with the pump timing by loosening the 3 nuts on the diesel pump pulley but............
 
what i mean if it makes any sence to anyone is the actual mechanism of the pump itself, should that be in a specificly set position when the crank, cam & flywheel are in their rightfull position
 
or am i completely of the boil, i remeber reading somewhere that someone had a pump issue where they needed a new pump & the place/chap that reconditioned the pump had to "RE-INDEX" the pumpthen when the person fitted the new pump it was the 3 nuts on the pulley wheel they had to fiddle with to get thie bus to run correctly
 
hope you chaps can help, i need to get my daily crewcab running again desparately!!!!!!!
i laugh at my own jokes cause there funny to me! i dont give a fck if you dont think they are


if your in the redline lol ya having a good time! lol ;P



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Post Options Post Options   Thanks (0) Thanks(0)   Quote ELVIS Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 02:32
ok
 
take out inspection bung on bellhousing. Turn crank round by hand (spanner/ratchet) whilst looking in the inspection hole with a torch (you might find arms arnt long enough to do both see need a helper.
 
 On the clutch there are 2 'horns' a few inches apart. Between these two horns there is a V shape notch. You want to line this notch up with the little metal pointer in the bellhousing. Your crank is now set to where it should be.
 
 Take rocker cover off and look at back of cam. In the back of it there is a slot cut across the width.If you look closelt you will see it is off centre. You need to fit a locking bar in this and if your anal use 2 sets of feeler guages to get the bar perfectly level.
 
 Look at the front of the injector pump pulley and you will see a hole that is noticabley smaller than the other casting holes. This needs to be set so that you can get a locking pin thr this smaller hole and into the hole in the backplate immediatle behind it when the hole is in approx 2 o'clock postion.
 
 If your engine is set up bob on then all the above 3 'settings' will all be spot on! You will probably find your are not by the sounds of it!
 
  Set flywheel as above as the other two are set from this. Check pump pulley hole, if it lines up all you need to do is undo cam nut (DO NOT se the locking bar while trying to undo nut-you will shatter the cam- wedge the pulley with a big screwdriver fo you dont have the right tool) and reset cam timing.  IF the pump is out you will need to undo tensioner as pump pulley is on a woodruff key and wont spin on spindle.
  
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ELVIS Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 02:34
 The three nut thing (4th at back of pump) is to set pump lift by slightly moving pump. Forget this for now.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote covdubber Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 03:19
i think i have set all as what you've said above! sorta makes sence to me lol
 
i'll take some pics as on my 1y pump pulley it only has the one hole (i think) to lock the pump in place i use a 6mm drillbit to lock it!
 
i had to mess with the cam timing as when i put the cylinder head back on & timing belt the motor was locking up :O/ fiddling with the cam position fixed this issue- so i can rotate the motor by hand without it locking up!
it also turns on the starter motor with no issues, fuel is in the pump & fuel lines
 
wish there was somone that live near me that could help me out, mean to be going to ireland in it in april :O/ gotta get her going again, i'm borroing a car for work at the moment & hate being low down
 
so i'll get pics tomorrow!
 
i do remember rotating the pump pulley when the belt was off but i cant for the life of me why i took the locking pin out & moved the pump pulley, i turned it untill the locking hole lined up again!!!!would that make a differance???????????
i laugh at my own jokes cause there funny to me! i dont give a fck if you dont think they are


if your in the redline lol ya having a good time! lol ;P



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Post Options Post Options   Thanks (0) Thanks(0)   Quote covdubber Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 03:19
cheers elvis for ya help so far chap!
i laugh at my own jokes cause there funny to me! i dont give a fck if you dont think they are


if your in the redline lol ya having a good time! lol ;P



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Post Options Post Options   Thanks (0) Thanks(0)   Quote kap k Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 06:50
Off the subject a little but did you turbo your lump or is it in the pipe line? Would like to hear how that goes.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote covdubber Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 11:44
my plan is to turbo it but igot heldbackwith thisblumminno-starting issue
 
basicly thecylinder headonthismotor is nowa recondition head,all thecompnants suchas timing belt/tensioner, glow plugs, alternator, water pump, alternator belt, clutch & release bearing battery & senders/sencers are all new, its only the block crant rods & pistons that are un-known but the engine (when running does'nt smoke or is'nt noisy & has good compression/oil pressure
so should be a decent motor to turbo ONCE SHE RUNS AGAIN lol
 
anyone offer anymore advice on the pump setup, is it in the bentley manual??????
 
am i right in thinking the diesel pump spindle should be in a set position to its body, which relates to the engine being at TDC to run correctly????
 
my understanding of diessel pumps isa bit novice to say the least! but getting there slowley!
i understand that the pulley on the pump that relases with the 3 bolts related to "fine adjustment" of the pump timing, a bit like a distributor on an older car
 
but from what ican gather the diesel pum must open valves or somthing  to send fuel to a certain injector at a certain critical point in time, so there for the pump spindle must be set to a critical position for the motor to run & fine adjustment for smooth running & correct idl is set with the pump pulley
& again even finer adjustment is done with the throttle cable backstop!
 
or i'm completely wrong, i think my theory is correct though lol
 
 
i laugh at my own jokes cause there funny to me! i dont give a fck if you dont think they are


if your in the redline lol ya having a good time! lol ;P



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Post Options Post Options   Thanks (0) Thanks(0)   Quote ELVIS Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 12:30
k
 
if the cam timing is set properly then thats all well and groovy on that front. (If you couldnt rotate it by hand before you prob had valve/piston intereference.)
 
 Is it making any attempt to start at all ?
 
Have you checked that the stop solenoid is getting 12 and all the othe obvious srtuff? pump properly primed.bled?
 
 The whole thing with moving the pump is to set pump timimg - as you say , not too different from dizzy. If you loosen bolts enough so you can move pump by giving it a good ole wack with the palm of your hand. Moving pump towards head advances timing, away from head obviously opposite effect. Did you scribe a line on bracket before you removed it to make sure it went back in right place?
  Get someone to start engine while you gently move pump to see if its out.TBH ive never had one not start/or attempt to start from timing being not set, might have just been lucky!
 
 If you dont have a DTi , when you get it running you can do timing by ear. Move towards head until you can hear a knocking noise then tap it backwards until noise just dosaapears. Nearly always ends up bob on when checked with DTi.
 
Good luck!
 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote light Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 13:06
Originally posted by covdubber covdubber wrote:

i think i have set all as what you've said above! sorta makes sence to me lol
 
i'll take some pics as on my 1y pump pulley it only has the one hole (i think) to lock the pump in place i use a 6mm drillbit to lock it!
 
i had to mess with the cam timing as when i put the cylinder head back on & timing belt the motor was locking up :O/ fiddling with the cam position fixed this issue- so i can rotate the motor by hand without it locking up!
it also turns on the starter motor with no issues, fuel is in the pump & fuel lines
 
wish there was somone that live near me that could help me out, mean to be going to ireland in it in april :O/ gotta get her going again, i'm borroing a car for work at the moment & hate being low down
 
so i'll get pics tomorrow!
 
i do remember rotating the pump pulley when the belt was off but i cant for the life of me why i took the locking pin out & moved the pump pulley, i turned it untill the locking hole lined up again!!!!would that make a differance???????????
 
Providing you have not undone the big nut  18-19mm on the pump your pump timing should be right if the locking pin is in the hole regardless whether you turned it or not ,when the pin is in it`s set at the correct lift
 
If the cam is locked of and the crank is set at tdc and the pin is in the pump the timing is correct providing the big nut on the pump have not been undone as most of the pumps with the pulleys with the three 13mm nuts  for adjustment{vernier pulley} are not keyed to the shaft
 
The 3  13mm nuts on the pump pulley are there to allow the correct tensioning of the cam belt and not for the adjustment of the pump timing {providing you are seting it to vw spec} as the pump timing is set buy the locking pin 
 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote covdubber Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 13:14
right i have to make some checks & do pics for you folk & for myself to confirm i've dont things in the correct manner!
 
it made one attempt at a cough rather than an attempt to run,
 
 
 
i think i may have had the diesel pump pulley off at one point to be honest!!! if thats the case do i have to take the pump off & have it re-set at a specialist?????  how much is the going rate for this???
 
its a flippin learning process lol :OP
i laugh at my own jokes cause there funny to me! i dont give a fck if you dont think they are


if your in the redline lol ya having a good time! lol ;P



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Post Options Post Options   Thanks (0) Thanks(0)   Quote light Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 13:43
If you have removed the big nut and removed both half`s of the pulley from the pump`s shaft and there was no key in the shaft {there will be a key way in the shaft but no key as the pulley will probably have no key way in it} then it is a bit of a bastard to set the pump to the correct lift at the point at which the locking pin fits but it can be set to the correct lift using the adjustable pulley and a D.T.I gauge but the locking pin will then be redundant
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Post Options Post Options   Thanks (0) Thanks(0)   Quote covdubber Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 14:05
do you mean as in a simular method to this


Edited by covdubber - 12 Mar 11 at 14:07
i laugh at my own jokes cause there funny to me! i dont give a fck if you dont think they are


if your in the redline lol ya having a good time! lol ;P



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Post Options Post Options   Thanks (0) Thanks(0)   Quote light Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 14:40
Yep that's only if you have removed both half`s of the pulley from the pump`s shaft if that is the case you will have to remove the complete pulley from the shaft and look at the inside of the pulley {the mounting surface for the shaft} for a mark where the key way on the shaft has sat ,and try to line the mark up with the key way on the shaft when you put it back on as there is a limit to the adjustment on the pulley so you must get it there about ,if you have just taken the outer of the pulley of {the three 13mm nuts} it is just a case of locking it with the pin
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Post Options Post Options   Thanks (0) Thanks(0)   Quote ELVIS Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 11 at 21:52
im a cock! teach me to speed read! missed vital clue it was obvioulsy a vernier, sorry!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote covdubber Quote  Post ReplyReply Direct Link To This Post Posted: 13 Mar 11 at 11:47
where do i get the adaptor for my dial gauge? do set my pump timing folks?
i laugh at my own jokes cause there funny to me! i dont give a fck if you dont think they are


if your in the redline lol ya having a good time! lol ;P



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Post Options Post Options   Thanks (0) Thanks(0)   Quote light Quote  Post ReplyReply Direct Link To This Post Posted: 14 Mar 11 at 11:20
Originally posted by covdubber covdubber wrote:

where do i get the adaptor for my dial gauge? do set my pump timing folks?
brickwerks  dose a gauge and adapter don't know if they do adaptor on it`s own
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