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Full Name: Mark Varley


Postby varleym » Fri Nov 19, 2010 9:34 pm

Got the timing cover off and just setting up to start removing the timing belt. Need to lock the engine at TDC before I start and 'alledgedly' TDC is achieved when you can pass a 3/8ths bar all the way through the hole in the injector pump pulley, however this doesn't allow the TDC mark on the camshaft pulley to line up with the fin on the casting which also denotes TDC (see photo's below).

Now I've read that the injector pump timing may be out but which has the greater degree of certainty - the mark on the camshaft pulley or the alignment of the holes on the injector pump pulley?


Photo showing alignment of holes in injector pump pulley
Photo showing mis-alignment of mark on camshaft pulley when engine set on injector pump timing alignment

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Postby kingsonlim » Fri Nov 19, 2010 9:51 pm

Mark, once the timing belt is off, you need to make certain of 3 TDC positions:

- 9mm or 3/8" drill bits fully into the slot on injection pump. You may loosen the 3 10mm bolt on the injection pump sprocket.
- the TDC mark on cam sprocket to be inline with the fin
- a 5mm drill bit to be inserted at the bottom of the bellhousing, right in the middle of the hole. You may also find a notch on the block where the woodruff key should be inline to.

Before fitting the timing belt, leave the 9mm drill bit in the slot, use a socket, turned the biggish nut (22mm I think) in the middle of the injection sprocket clock wise to the max, mark it, then turned it anti-clock wise, mark it. Now position the sprocket to the middle of both marking.

Fit the timing belt, tighten the tensioner & the 3 bolt on the injection sprocket. Then make sure cam sprocket and crank sprocket are aligned to the fin and notch.

You can re-adjust the injection timing once the vehicle is complete, by removing the inspection hatch, loosen the 3 bolt, and turn the injection pump center nut. (clockwise for retard, anti-clock wise for advance)

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Postby varleym » Fri Nov 19, 2010 10:10 pm

Cheers mate

:D :D

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Postby Bo » Sat Nov 20, 2010 9:18 am

Mark, use a wading plug and drill a 5mm hole on the centre, you can then screw this in to the bottom of the bell housing with the shank if a 5mm drill in it and lock the crank at TDC. With a drill in the pump and the crank locked, it's plain sailing.
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Postby Matthews » Sat Nov 20, 2010 1:35 pm

Fit the belt concentrating on the crank and cam pulleys, then adjust the injection pump to suite, turn engine over 2 or 4 times with socket on crank bolt, recheck and hopefully everything still lined up and hey presto your done , don't forget to remove locking tool from bellhousing before attempting to turn engine over though.

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