Squidward 23

hello all,
Have just spent several weekends stripping down and rebuilding my old 1991 200tdi defender engine.
replaced all things that were a little worn. Had pump serviced as well as injectors by Cochester diesel injector specialist. Set timing of pump with crankshaft. ensured I had good power from battery no air in fuel system and a set of brand new glow plugs. My compression was 1. 430psi 2. 465 3. 465 4.455psi. I measured the protrusion of the piston from the block and got a 2 hole gasket.
the head was skimmed and a superficial crack was mended between the valves of cylinder 3.
BUT!
It does not start???

I have followed some threads suggesting easy start sprays but equally many threads warn against this ???
I have checked for fuel at injectors air bubbles at back of pump and filter have nice pressure in my uplift pump when on heel of camshaft lobe?
Stop solenoid cliks with power introduced.
I have rechecked pump timing with crank shaft and the timing pin slides in fully and out a gain?
I have torqued the rocker shaft as per spec and set valves at 0.2mm.
I have oil pressure!
Have new glow plugs and power at the glow plug.

Have no idea why the old beast refused to spring into life any helpful suggestions would be gratefully appreciated.

Lines up on flywheel through the wadeing plug hole?
You need to enlign the camshaft too, did you know?

piston height is used to determine gasket needed ,but with an unskimmed head , if too much is skimmed of you will need a thicker gasket
when you insert flywheel pin you need to check the key in front of crank is at 12 oclock, it might help to crack injectors pipes of and spin engine over till fuel squirts out

Thanks gents,
I timed up the cam with pump and crank and the woodruff key was at 12 o'clock. Got fuel at the injectors butane need to repeat this ? The point about the gasket has been niggling me , but being a rank amateur assumed if there was no valves crashing against Pistons it was ok?? Thanks again for your help.

I feel that you've done something not quite right with the timing. The FIP has to be locked ,with the keeper plate, in the correct position, then set up the crank and cam and then try the pin fit in the FIP, you slackern the 3 bolts to move the pump pully so the pin (9.5mm?) Goes in then retighten the 3 bolts. Re install keeper plate to unlock the pump.
My post isn't an exact 'how to' cos I'm going off memory but its all there in the Haynes manual. If your now thinking ' wtf is the keeper plate?' That is probably where your issue is.

Thankyou Flossie,
Am I wrong in thinking that for every revolution of the crank shaft ie from TDC to TDC where the flywheel slot lines up with bottom hole two groove lines up with the top hole and the crank key is at 12 noon you should always be able to push in timing pin in to FIP at the 10 to 10 position?

It's been too long since I've done it but the camshaft revolves at half what the crank does iirc.
Have you removed the keeper plate and tightened the bolt to lock the pump at all??
I suspect your camshaft dot isn't enligning with the arrow when the crank is correct and the pin fits the pump.
Whip the cover off and start again .
Have you got a Haynes manual?
To answer your question... I'm fairly sure you need 2 full turns on the crank for the pin to go in.