2.5 na fuel pump issues.

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Mark22_2

Mark22_2

Member
Posts
10
Location
Calne, Wiltshire
Hi, I brought my 1985 90 2.5 na with a known leaking fuel injection pump. Its local and was driving upto that point.
I've had the pump refurbished and also fitted a new lift pump.
I've set the timing as per dots on the 3 pulleys and tensioned belt etc.
The bit I'm struggling with is the pump timing! The tool doesn't want to drop into the hole inside the pump when I twist to advance / retard.
The engine starts on old timing pointer Mark's but sounds like its babbling back through inlet and occasionally there is a small tap from engine if revs are lifted. Also its pouring white unburnt fuel smoke out of exhaust.

Any ideas where to go next? I've had rocker cover off and everything looked to be opening/ closing as it should.
Thanks
Mark
 
The 12j from what I recall has no adjustment in the pump pully so with the crank and cam pully's set to marks feed the belt on starting at the crank then up to the cam and if necessary turn the cam pully clockwise until the belt teeth fit. Same goes for the injection pump pully, turn a bit clockwise to slip the belt on. When the tensioner is done up things should line up. [ well as close as can be with the 12j set up ] It does sound as if yours is one tooth out on the belt.
 
12j pump is adjusted by slackening the 3 securing nuts and injector pipes, you align marks fit belt,tension turn over twice re-tension and check marks,you then slacken the pump remove the plug in the side look at the disc through the hole or use the pin to find the notch by rotating the pump body
 
Cheers guys, I've re done the timing so many times and still not right! What you've both said is exactly as manual so must be another issue!

Any ideas where to go next? Injectors?
 
Mark22_2 said:
Cheers guys, I've re done the timing so many times and still not right! What you've both said is exactly as manual so must be another issue!

Any ideas where to go next? Injectors?
Click to expand...
injector pump pulley will have 2 marks a dot and an f,and crank should be set at exhaust peak 108 degrees btdc
 
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Ok, so stripped it all back down and started again. There is no place for the flywheel lock to engage which is strange. The hole in casing is there....
Checked ep points and lined everything up, slightly moving cam clockwise and she fired !

Now its smoking like a pig, its smelling a bit like fuel in the Smoke.
I've moved it a few mm towards the engine ( clockwise if looking at cambelt) it's not getting any better.
Does anyone think injectors could be a problem?
 
Nice link... thankyou. Wondered why I've never seen before then realized it's only a few days old.

I've done what the manual and video shows to the T.
Think I may pull the head for a look but will test the injectors as per video next chance I get.

Thanks
 
So.... update.
Head is knackered! Gasket between 2 and 3 is missing
2 and 3 have cracks between valves and up into the base of injector seats!

Explains alot...... should have trusted I was timing the pump correctly in the first place.
Now to try and source a 12j head..... not a easy task.
 
Mark22_2 said:
So.... update.
Head is knackered! Gasket between 2 and 3 is missing
2 and 3 have cracks between valves and up into the base of injector seats!

Explains alot...... should have trusted I was timing the pump correctly in the first place.
Now to try and source a 12j head..... not a easy task.
Click to expand...
Heads on their own might be hard to find but you see complete engines on fleabay often for little money - ususally removed for a tdi upgrade.
 
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