200TDi Timing Belt and Valve Adj - Page 2 - Defender Source
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  #21  
Old September 1st, 2015, 07:22 PM
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Did you try the rotation resistance test that I mentioned?
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  #22  
Old September 1st, 2015, 07:53 PM
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Quote:
Originally Posted by sonoronos View Post
One easy check to make is that when the injection pump timing pin is located in the hole, the resistance against rotating the injection pump pulley should "peak".

In other words: You'll notice when rotating the IP pulley that certain degrees of rotation meet more resistance than others. This resistance should be about maximal when the pin is centered and you should feel spring tension in the IP pulley actively trying to move the injection pump off center without the timing pin inserted.
Totally missed that! but very reassuring because that's what it feels like now. no chance of the pin going in but I moved the cog one tooth over and it was a pain because I had to hold pressure against the IP and get the belt in and tensioned one handed.

This is what the range looks like now:



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  #23  
Old September 1st, 2015, 08:59 PM
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starts, lots of white smoke. might be an adjustment away from success...
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  #24  
Old September 1st, 2015, 09:00 PM
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Sounds like you've found your problem, cheers
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  #25  
Old September 1st, 2015, 09:09 PM
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I'm just now seeing this thread, but yeah, your idle was bad. I drove Dan's 300 Tdi a week or so later and it is a night and day difference. You need to get in another 200/300 Tdi truck to see how it should feel. I only was just taking a guess based on no experience at it being timing or valve adjustment. When I looked up how to do the valve adjustment on my old truck I remember people saying it made the truck run much smoother. I want to reiterate that yours was very bad, and when its fixed you should notice a huge difference.
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  #26  
Old September 1st, 2015, 09:42 PM
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She's running, and it really is nice and quiet. setting the valves was easy and its noticeably quieter.

The last iteration of IP timing went from:

- Full counter clockwise starting with lots of smoke with a very flaccid rev up.

- Full clockwise it sounded like an old army 5k generator.

So I went smack dab in the middle by feel, locked it in, bam success! Thanks for all the help everyone. Not you Jimmy you ruined my afternoon.

By the way this is what it looks like, I might fit a 4.5mm pin in there for future reference.

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  #27  
Old September 1st, 2015, 09:44 PM
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So to be clear, with all of the timing set using the tools it doesn't run properly?
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  #28  
Old September 1st, 2015, 09:51 PM
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Oh no it works great now. But lining it up with the 9mm pin (9.36 or whatever) it wouldn't run.

I probably should have gave myself more adjustment clockwise than I did initially. I also ran with the idea that I was off a tooth which didn't really pan out. I haven't put a drill bit in there but I'm guessing 4.5 ish seems about right.
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  #29  
Old September 1st, 2015, 10:51 PM
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My best guess is that somebody didn't clock the IP properly. It would probably make more sense at a future date to clock the IP with the correct tool instead of trying to find a 4.5mm pin.
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  #30  
Old September 1st, 2015, 11:31 PM
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I will consider doing it in the future. I'll take her for a spin tomorrow and see how I like it.

Thanks again everyone.
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