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300tdi injector nozzles are 2 stage and most pop testers can only test the first stage and the second stage is the most critical. Best if you take them to somewhere that is familiar with that type of injector.

No I never did sort it. I made doubly sure that the starter solenoid works fine and it does, just as soon as it gets power. I even took it out and cleaned the sliding part. Somehow or other, turning the key does not power up the solenoid instantaneously. I think there is a relay in...

98 Discovery with 300tdi, formerly v8. I turn starter and often, not always, there is a couple or three second hesitation before the starter turns and the engine starts. I have done some checking and the hesitation seems to be that the starter signal going to the solenoid from the switch...

Looking at the front of the engine timing cover, l.h. side, you will see a round plate held on by 3 screws. If you have aircon its behind the belt tensioner. Remove that and you will see the drive sprocket of the Injector pump. There are 3 bolts which allow for fine tuning of the timing...

I have read this whole thread with great interest. I have made some small adjustments to the diaphragm and smoke screw and felt the improvements. What made the biggest improvement for me however (not seen mentioned yet) is a very small advancement of the injector timing. I did the timing...

If your glow plugs are wet, it might be the valve stem seals letting some oil get by when the engine is stopped. They could also be wet from fuel if the injectors are high miles and leaking a bit when engine is off. If the engine starts quickly and power is good, its probably not rings.

The manifold is in three pieces so you may also want to check how they go together and use a high temp exhaust sealant where they slip together. Your smoke on the overrun may be due to slight late injection timing. Try advancing it a smidgen (20 thou or 0.5 mm at the three pulley flange...

I found it tough to get the ball end of the clutch rod into the seat on the lever. There is a plastic clip that you can use to keep it in place while the slave cylinder is slid over it. Make sure that gets assembled right. The clip isn't 100% necessary but it does make the job easier I found...

Usually pumps with EDC dont have a lever to connect a cable. All is done electronically.

Yes you can. However due to the shape of the transfer box, it is a royal pain to do it that way. You almost need to construct a cradle so you can keep everything at the right angle while you lift it in place.

Aha, I got it wrong. I knew it was in one piece and not the other. I picked the wrong piece. I wonder why they did that? Steve

I totally agree but where this guy is located, getting it reset properly might be a big challenge. Plenty of expertise on VE pumps but anything specific to 300tdi will be hard to find.

I think there is a keyway in the pulley but no key in the shaft. Sometimes there are stains in the taper which you can just line up with the keyway and get it pretty close before locking it down. I'm sure there is a more scientific method but can't find it off the cuff. Steve

You could try checking the timing with tools for an older non tdi VW Rabbit or Jetta. Remove the bolt in the center of the injector pipe fittings and screw in the tool with a dial indicator. You will need the short tool, otherwise the vacuum pump will be in your way. Check google for timing a...

get someone to advance the timing a very small amount, like .020" or 0.5mm at the three pulley screws max. You will be pleasantly surprised by the results.

I suppose thats possible. Normally the cold start is accomplished by a slight advancement of the timing and its done right at the bottom of the pump. On older VW's for instance there was a cable to pull, a bit like a manual choke, that you push in when the engine is warm. I don't see...

Well I have left it alone for some time. As an engineer, somehow I need to know what its for. Perhaps I could be getting 0.1 more mpg or even 0.2 HP more or something really important :-)

This is not my pump but one on ebay that is just like it. The lever I question is clearly shown. It looks like an inverted "T" close to the top of the pump, behind the black fuel line. The long spring is quite visible too...

My 96 Disco injector pump has a lever the function of which I do not understand. Perhaps someone here can fill me in. On the side of the pump closest to the engine block, there is like a vertical lever close to the top of the pump body. This lever has an adjustable push rod attached to it with...

Well I fixed mine with a US penny so I reckon my fix was about 40% cheaper than yours ;-) Steve