P38A Fuel pump timing chain

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gkm24

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24
Location
Hampshire
Just fitted a second hand engine to my Diesel P38 2.5 which came minus the fuel pump.
I do not know if the engine was turned while the pump was removed and need to check that the fuel pump sprocket is in the correct position. I can not find this info in the manual and wondered if anyone can enlighten me please.
Many Thanks.
 
If the pump has been removed without sprocket holder in place tensioners will have pulled sprocket out of position and you will not get pump back in. At TDC number one firing woodruff key in sprocket should be uppermost.
 
Last edited:
wammers said:
f the pump has been removed without sprocket holder in place tensioners will have pulled sprocket out of position and you will not get pump back in. At TDC number one firing woodruff key in sprocket should uppermost.
Click to expand...

So the woodruff key should be at the 12 O Clock position?
Will I have to remove the timing cover to correct this or can I perhaps jiggle it into the correct position?
 
gkm24 said:
So the woodruff key should be at the 12 O Clock position?
Click to expand...

Yes. If the pump has been removed without the sprocket holder in position and the tensioners have not been pinned back you have problems. Pump should not be removed unless sprocket holder is in place and engine is locked at TDC. You may have to remove front cover and re time engine
 
Grrrrrr said:
If no FIP then it will already be pulled out of reach, won't it? So he must either have a FIP in or more likely the covers off?
Click to expand...

Yes if the pump has been removed without the sprocket holder being in place then the tensioners will have extended and pulled the pump sprocket out of place. Turning the engine could cause all sorts of problems. Front cover needs to come off in my view. But several special tools are needed to achieve this as you will know. It's not a weekend mechanic job.
 
Not to worry, I served 20 years with BMW but these engines came in just before I changed tack so did not get that involved with them.
The pump is fitted but I'm not sure that the FIP sprocket was in the correct position(the woodruff keyway). I have stripped off the front cover of the old engine and been playing with that so I can get a clear view of whats actually happening.
I have all the proper tools needed but short on time.
I set the old engine up on TDC and noted the position of the notch on the crankshaft timing sprocket and counted 12 links to the 6 on the FIP sprocket.
The manual says "Assemble sprockets to lower timing chain.Ensure dimples on sprockets align with chain’bright’ links"
There is a dimple on the crank sprocket, but to get the FIP sprocket so that the keyway is at 12 O'clock the other "Bright Link" has to align with the 6.
Does this sound familiar?
Appreciate your help.
 
gkm24 said:
Not to worry, I served 20 years with BMW but these engines came in just before I changed tack so did not get that involved with them.
The pump is fitted but I'm not sure that the FIP sprocket was in the correct position(the woodruff keyway). I have stripped off the front cover of the old engine and been playing with that so I can get a clear view of whats actually happening.
I have all the proper tools needed but short on time.
I set the old engine up on TDC and noted the position of the notch on the crankshaft timing sprocket and counted 12 links to the 6 on the FIP sprocket.
The manual says "Assemble sprockets to lower timing chain.Ensure dimples on sprockets align with chain’bright’ links"
There is a dimple on the crank sprocket, but to get the FIP sprocket so that the keyway is at 12 O'clock the other "Bright Link" has to align with the 6.
Does this sound familiar?
Appreciate your help.
Click to expand...

Yes it should have a 4 and a 6 on the pump sprocket. 4 is lineup for 4 cylinder engines 6 for yours. Don't forget to tighten the crank bolt correctly or you will lose the oil pump.
 
Thanks for the reply. When I line it up with the six on the FIP sprocket, the keyway is not quite at 12'O clock but about one tooth out. Can you confirm this.
Sorry to be a pain but just don't want to pull it apart and get it wrong and then have to do it again.
Manual is not very clear at all.
 
Please see attached pic.
 

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gkm24 said:
Please see attached pic.
Click to expand...

That is fine i never could tell the time. As long as you have the bright links lined up on the crank sprocket and the 6 on the pump sprocket. Get the pump in place and the sprocket on it, tensioner dropped. It will not be a millions miles from 12 o'clock. Hope you are checking the chains for tooth ache. New chains at least maybe a good move.
 
Last edited:
Lol. Thanks for the reassurance. Got some chores to do between now and the next time I look at it. I will update on progress.
 
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