200 tdi timing

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RichDevon90

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Posts
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I am rebuilding a 1990 200tdi engine and just put the timing belt on. The head isn’t on yet.
On checking the TDC ( pistons 1 and 4 at the top) the timing appears to be set at 4 rather than 1.
The crank woodruff is straight up, the cam pulley mark points to the arrow and the pump is locked with a 10mm drift.
Does anyone have any experience of the timing being set on piston 4 at TDC?
 
We put two con rods in the cam followers and rotated the crank to establish the firing position for no 1 piston. It appears to line up on 4.
We rotated it twice.
With the timing belt on and the timing marks aligned rotating it twice comes back to the same alignment.
We’re inclined to build to the timing arrows and start it on the ground and see what happens.
 
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Edit for sphelling!
 
Last edited:
Iirc, the pump lock is 9.5mm, a 10mm won't or shouldn't go in.
Have you locked the flywheel too?
I've done this job twice but a good while ago so my memory isn't the best but I don't recall it being difficult. I just used the haynes manual for both full rebuilds.
 
meego said:
Just for my info, why them ?
Click to expand...
No particular reason, but the times I have seen them on tv they have had some interesting/expensive cars for sale, so I have to assume people who buy interesting/expensive cars would be watching what is coming up for sale.
 
Flossie said:
Iirc, the pump lock is 9.5mm, a 10mm won't or shouldn't go in.
Have you locked the flywheel too?
I've done this job twice but a good while ago so my memory isn't the best but I don't recall it being difficult. I just used the haynes manual for both full rebuilds.
Click to expand...
The flywheel is still off as the block is on an engine stand.
The pump has been professionally rebuilt and we assume by locking it it will match TDC on no 1 and the cam pulley will match the timing marks.
 
RichDevon90 said:
The flywheel is still off as the block is on an engine stand.
The pump has been professionally rebuilt and we assume by locking it it will match TDC on no 1 and the cam pulley will match the timing marks.
Click to expand...
What are the cam lobes for cyls 1 and 4 doing when at tdc?
The inj pump might have the keeper plate locked up, check before trying to start the engine.
 
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