TDi injector pump

[hillbillie53]

Hi to all, does anyone know what the injector pump setting should be for my 1998 2.7 TDi with a " fly by wire " Bosch pump is ? My workshop manual states a dial gauge reading of 0.38mm +/- 0.02mm at TDC but this is for the older cable type pump for the 100bhp engine. Is the setting the same?

 

[BIGSEAN]

Just changed my pump recently all i did was set it roughly where my old un was and hope for the best. And luckily it seems to be spot on,good power and fuel consumption in the high 20s/low 30's

 

[hillbillie53]

Did the same but grey smoke when revved above 3K and hestiates above 2K. Been told it's running weak because the pump is not lifting enough ,so thought if I've got to do it, do it right! It will be a first when if happens! Someone with knowledge said turn the pump about 1mm to the right when viewed from the front and see how she runs?

 

[cncfabs]

Did the same but grey smoke when revved above 3K and hestiates above 2K. Been told it's running weak because the pump is not lifting enough ,so thought if I've got to do it, do it right! It will be a first when if happens! Someone with knowledge said turn the pump about 1mm to the right when viewed from the front and see how she runs?

If they had knowledge they would have showed you how to do it right:thumbs i was told once if you get the timing wrong and it fires at tdc the engine would blow up

 

[11redrex]

I got told if I unscrewed my belly button my bum would fall off.

 

[Toolbox]

http://bebrs.pie-dabas.net/Webs/Terrano/R20/ec.pdf

page 339


If your pumps ok! I would check your turbo wastegate isn’t stuck open or the operating rod has undone. Very similar symptoms .

 

[hillbillie53]

Turbo is fine had it re-con'd at the start of problems. Have turned injector pump about 1mm clockwise to advance it, now it won't start. Turned it back to original position and still will not start!!!! About to strip inlet manifold off, take the rad and preheaters out and do the damn job properly. If it still won't run properly will take the thing to the garage!
thanks for the advice.

 

[leafy1]

I copy and pasted this info from the online manual as stated a few posts up.I adjusted my bosch pump using a dial gauge this way.

Have you had the pump off at all and do the timing marks line up.Also I know I keep going on about it but if the mini filter in the banjo on the pump is dirty the engine will run terrible especially if you have been taking fuel lines on and off......before you do anything else check the filter first if there is one.


CHECK INJECTION TIMING.
1. Set No. 1 piston at TDC on its compression stroke.
2. Remove injection tubes and air bleeder
on the back of injection pump.
3. Set dial gauge so its indicator points to
somewhere between 1.0 and 2.0 mm
(0.039 and 0.079 in) on the scale.
4. Turn crankshaft two turns clockwise
and check that dial gauge indicates the
same value again.
5. Turn crankshaft counterclockwise about
100 degrees, then turn crankshaft
clockwise slowly, and set dial gauge
indicator to 0 mm at the position it
stops.
6. Turn crankshaft clockwise and set it at
TDC using the mark on the crankshaft
pulley.
7. Read plunger lift.
Plunger lift:
0.36 ± 0.02 mm (0.0142 ± 0.0008
in) at TDC
I When repeating the checking, start
with step 5



Adjusting
1. If plunger lift is not within the specified
value, adjust by turning injection pump.
I If indication is smaller than the
specified value, turn pump body
away from engine.
I If indication is larger than the specified value, turn pump body towards
engine.
2. Tighten injection pump securing bolts
and nuts.
Nut:
: 20 - 25 N⋅m
(2.0 - 2.5 kg-m, 14 - 18 ft-lb)
Bolt:
: 32 - 42 N⋅m
(3.3 - 4.3 kg-m, 24 - 31 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 20 - 25 N⋅m
(2.0 - 2.5 kg-m, 14 - 1

 

[11redrex]

Are you sure there's not an air leak in the system somewhere ? Using clear pipe between the filter and the metal pipe will show any bubbles.

 

[hillbillie53]

Swapped my old pump across from my old engine when I fitted a replacement short engine and didn't note the pump timing, so know the pump will be out of sync. I was warned about possible air bubbles in fuel and found none as the fuel line had already been replaced. Many thanks for the timing info will re-time pump with dial gauge when the weather gets warmer ( sad or wot! ) Will let the know if it's worked hopefully within the next couple of weeks.

 

[leafy1]

Swapped my old pump across from my old engine when I fitted a replacement short engine and didn't note the pump timing, so know the pump will be out of sync. I was warned about possible air bubbles in fuel and found none as the fuel line had already been replaced. Many thanks for the timing info will re-time pump with dial gauge when the weather gets warmer ( sad or wot! ) Will let the know if it's worked hopefully within the next couple of weeks.

I can remember when I changed mine over too when doing a rebuild with another engine(The engine I used had a Zexel pump which I had to take off and switch for my Bosch pump.............unfortunately I kept the Zexel pump timing gear wheel in my plastic parts bin at the time, somehow dopey me fitted the Zexel gear wheel to my Bosch pump when doing the swap(They look and fit exactly the same and timing marks seemed to line up....................but after close inspection there is a slight difference)The Terrano would just about start but wouldn't idle and ran like a bag of nails.I did all sorts turning the pump trying to get the dial setting correct but it just wouldn't have it.It wasn't until I glanced over the parts bin and saw the other gear wheel that I knew what I had done wrong :doh.Changed them over in a matter of seconds and could get the correct dial reading then, first flick of the key the Terrano started :thumb2

 

[hillbillie53]

light at the tunnel end

Followed Leafy1 excellent detailed instructions and found that pump was about 15deg retarded. Was unable to the time pump within the adjustment slots so finally set up pump with correct lift then removed pump gear and turned engine back to TDC and re-fitted pump gear! Engine now lifeless? Finally bled the pump using the centre screw which I had removed to insert the dial guage. The engine then started and ran beautifully with no smoke !!!
Just passed it's MOT and after 6 long months of ownership now hoping to finally enjoy driving it!
Thanks to all for the advise.

 

[mjpetersen]

Sweet!!

:clap:thumb2 Enjoy not only your truck, but a keen sense of accomplishment. :thumb2

 

[leafy1]

Great news :thumb2