Hi, sorry for delay in replying, working away has its downfalls. these pics hopefully will prove what I have been saying about this particular engine, just because you havent come across it before dosent mean it cant happen,
Kev have you still got your old engine? Might be worth sticking the flywheel back on it and checking position of keyway with lock pin engaged. If it's the same on both engines that would prove a point as the other one has run. What position is the dot on the crank sprocket with the engine as is in your latest photo? It should be almost straight down with lock pin in. That would then match the illustrations in RAVE. I still don't think lock pin was in correctly in your first set of photos showing relative positions of chain links and dots on crank and pump sprockets. Think that has thrown us off course a bit. Maybe the arrow on the pump body indicates 20 degrees BTDC where pump should be off cam and BMW use for pump timing in the factory. I am fairly confident you had the lock pin in wrong when you timed the pump. Rebuild it with lock pin as is and time the pump. I am fairly confident it will then run as it should.
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