200 DI pump timing.

Citizen Kane · Sep 13, 2015

Hi, new to the forum and new to Land Rover ownership. I'm in the final stages of a Series 3 preservation and have fitted a Discover 200 TDI engine.

I had a few problems with smoke and a misfire when I started it up and have eventually tied it down to pump timing.

By advancing the pump timing a couple of degrees the engine now runs fine but I cant confirm the timing is spot on as the gearbox cross member obscures the flywheel timing plug and the TDC mark on the crank pulley is a rather rough indication and not accurate enough.

What do fellow Series 200 TDI / DI owners do to locate TDC. I could probably drill a large hole in my nice galvanized chassis cross member, any other ideas or recommendations.

jamesmartin · Sep 13, 2015

Citizen Kane said:
Hi, new to the forum and new to Land Rover ownership. I'm in the final stages of a Series 3 preservation and have fitted a Discover 200 TDI engine.

I had a few problems with smoke and a misfire when I started it up and have eventually tied it down to pump timing.

By advancing the pump timing a couple of degrees the engine now runs fine but I cant confirm the timing is spot on as the gearbox cross member obscures the flywheel timing plug and the TDC mark on the crank pulley is a rather rough indication and not accurate enough.

What do fellow Series 200 TDI / DI owners do to locate TDC. I could probably drill a large hole in my nice galvanized chassis cross member, any other ideas or recommendations.

mark on crank is ok crank and cam have to be out a tooth if they are out so its fairly noticeable ,pump can be advanced till it runs right

Citizen Kane · Sep 14, 2015

I guess that's where I am, advancing the pump until it seems OK, I would like to get the timing spot on, the difference between running rough, misfiring, producing loads of eye watering smoke and running clean was only about 2 or 3 crank degrees, if its that sensitive it would be nice to know if its now correct or still some way away from optimal. Might just go ahead and cut a hole in the cross member.

jamesmartin · Sep 14, 2015

pump timing is that sensitive, cam and crank can be only 1 tooth if the needed to be exact cam would be adjustable as well,even if you use rear pin in flywheel its still best to advance pump till optimum which is just before knock,

Citizen Kane · Sep 14, 2015

At what point should I be listening for knock, should the engine be under load and revving hard or just on tickover. I guess the pump must have some kind of advance retard mechanism, do I need to be revving high enough to be at full advance?

jamesmartin · Sep 14, 2015

at idle

Citizen Kane · Sep 14, 2015

Thanks for the information, will have a go this weekend and see how I get on.

Webley1991 · Sep 14, 2015

I recently changed an injection pump on a Shogun. The shogun pump is very similar to the pump fitted to the 200Tdi. Both are based on the Bosch VE design.

I timed the Shogun pump using a dial gauge. See this video for the procedure for a 200Tdi engine.

Citizen Kane · Sep 14, 2015

The problem with that technique is it requires the engine to be accurately positioned at TDC, I don't have easy access to lock the flywheel with a timing pin hence having to in this case advance the timing until I think its about right. Stupid thing is I could have done all this when the engine was on the bench, I brought the engine fully rebuilt with a new belt already fitted, just assumed it would have been timed correctly when it was reassembled.

jamesmartin · Sep 14, 2015

if you have drill bit set you can start with 9.5 which is pump timing pin size ,insert pin slacken the 3 bolts and hold pump nut with a spanner clockwise against the pin then tighten the 3 bolts ,try engine repeat with a 9mm then 8.5 etc etc till youi get knock then go up a drill size till knock goes

Webley1991 · Sep 14, 2015

Sorry, I should have read the first post more thoroughly.

I am actually very inexperienced with this sort of work, the Shogun pump was the first time I have done anything like that.

Can it be described what knock actually sounds like? Diesel engines rattle at the best of times, even when they're running smoothly.

jamesmartin · Sep 14, 2015

if you advance enough youll hear it

200 DI pump timing.

Citizen Kane

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