Help with 200TDi injector pump

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markomate2

markomate2

Well-Known Member
Posts
898
Location
Bedford and Tallinn
Hi
Ive been helping a mate with his 200TDi Defender.
Cant get it started after a rebuild.
Had the pump "checked and cleaned" by a local specialist.
We narrowed the problem down to the following:
After removing the toothed drive wheel, we then removed the drive flange that the wheel is bolted to.
The drive flange is attached to the pump drive shaft by a taper on the shaft, the shaft also has a key slot.
BUT there was no key in the slot and no slot on the flange!
So the only thing stopping the flange from turning on the shaft was the friction of the taper.
Has anyone stripped down the TDi drive wheel/flange?
We have done a lot of searching but cant find a decent pic confirming if the drive flange should have a slot.
Thanks
Mark
 
markomate2 said:
Hi
Ive been helping a mate with his 200TDi Defender.
Cant get it started after a rebuild.
Had the pump "checked and cleaned" by a local specialist.
We narrowed the problem down to the following:
After removing the toothed drive wheel, we then removed the drive flange that the wheel is bolted to.
The drive flange is attached to the pump drive shaft by a taper on the shaft, the shaft also has a key slot.
BUT there was no key in the slot and no slot on the flange!
So the only thing stopping the flange from turning on the shaft was the friction of the taper.
Has anyone stripped down the TDi drive wheel/flange?
We have done a lot of searching but cant find a decent pic confirming if the drive flange should have a slot.
Thanks
Mark
Click to expand...
flange doesnt use a key pump is supposed to be locked at tdc by removing a spacer from the lock bolt and screwing in,before flange is removed
 
Hi James
Yes thats whats so frustrating about it, we checked and rechecked everything during a long, wet day yesterday.
Basically the engine cranks over fine, fuel at the injectors, lots of white smoke, unburnt fuel.
So that points the finger at timing.
Starts on Easystart, stops as soon as the Easystart is off.
Seems to be a common issue with rebuilt TDi,s, usually traced to wrong belt positioning.
But what we found was even with all the pins in place, its possible for the pump shaft to move because theres nothing to stop it, no key.
So I guess its not a problem if the pump shaft is locked, by the small bolt on the side, BUT thats assuming the drive flange was put back in the correct place by the people who checked it!
So what we are trying to do is to establish the relative position of the drive flange to the slot with the pump out of the vehicle, thats what we cant find any info on.
Hope thats clear!
Mark
 
Last edited:
markomate2 said:
Hi James
Yes thats whats so frustrating about it, we checked and rechecked everything during a long, wet day yesterday.
Basically the engine cranks over fine, fuel at the injectors, lots of white smoke, unburnt fuel.
So that pints the finger at timing.
Starts on Easystart, stops as soon as the Easystart is off.
Seems to be a common issue with rebuilt TDi,s, usually traced to wrong belt positioning.
But what we found was even with all the pins in place, its possible for the pump shaft to move because theres nothing to stop it, no key.
So I guess its not a problem if the pump shaft is locked, by the small bolt on the side, BUT thats assuming the drive flange was put back in the correct place by the people who checked it!
So what we are trying to do is to establish the relative position of the drive flange to the slot with the pump out of the vehicle, thats what we cant find any info on.
Hope thats clear!
Mark
Click to expand...
yes the should have fitted it correctly but if flange has moved on the shaft it wont be now, it only needs locking if flange is coming off ,you could get the guy to reset it ,but key should line up with no1 injector outlet, but thats only rough to get it right you use a dti and a rod to fit through rear of pump to find exact plunger lift point the fit flange using the timing pin
 
Cool thats the info we needed.
My mate is going to call them Monday.
Still find it strange that the pump has a slot for the key but the flange doesnt and just relies on the 22mm nut being tight!
In my book a taper lock shaft should always have a slot/key!
Thanks
Mark
 
markomate2 said:
Cool thats the info we needed.
My mate is going to call them Monday.
Still find it strange that the pump has a slot for the key but the flange doesnt and just relies on the 22mm nut being tight!
In my book a taper lock shaft should always have a slot/key!
Thanks
Mark
Click to expand...
taper fit with no key is very popular now a lot of cams etc are the same
 
Thought Id close my thread off.
All sorted today, we removed the pump, again, and checked the relation of the slot in the shaft to No1 outlet port.
Turned out that at No1 TDC it had been aligned with No 3 injector outlet port!
So although the timing pins fitted and everything lined up, because the flange that the toothed wheel was bolted to, was in the wrong place, the timing was wildly out!
The local specialist was in Colchester.
Realigned slot with No1 port and used a DTI kit to time correctly.
Put it back together and she fired up first turn, even on todays chilly day!
Bit smoky on reving up but first start after a big rebuild and the exhaust system is still probably full of diesel from the attempts at starting before.
So quite happy with todays work.
Mark
 
markomate2 said:
Sorry Jamesmartin I forgot to thank you for your heads up on the slot position.
Cheers!
Mark
Click to expand...
Hi
I don`t know if you can help me
My tdi200 has a Bosch pump which is leaking from the small bolt in the centre of the rear between the injector outlets
Can you tell what it is for and possibly why its leaking?
 
A grown up will confirm but I think it's the access port for a DTI. If you remove the bolt it will have either an O ring or probably a copper washer which has failed.
 
This help
ve_blowup.jpg
 
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