200tdi turns over but will not start

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GuamBomb

GuamBomb

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46
Location
Rota Spain
I'm rebuilding a 1991 Defender 90 with a 200tdi engine. I replaced the fuel tank, fuel pump, and hoses. I also replaced the timing belt. The engine turns over but will not start. After reading through threads, I bled the fuel system by cracking the injectors while it was being turned over. I have good fuel flow going to all of the injectors but it still will not start. I'm pretty sure I lined up the timing correctly when installing the timing belt. Anyone have any suggestions on what else to trouble shoot before I go to all the trouble of pulling the timing cover off again to recheck it?
 
put crank pin in rear remove the pump cover so you can insert pump pin take off rocker cover to ensure both valves on no1 are fully shut both valves on no4 are partially open
 
So I went ahead and pulled the timing case cover off completely just to be sure I have every thing lined up correctly. I have the crank pin in and it is sitting at TDC per the mark on the crankshaft pulley. The FIP pin is in and its sitting at the 10 o'clock position. The camshaft timing mark is also in line with the arrow on the case. Here are some pics with the rocker cover off. Does this look correct?
IMG_2167.JPG
IMG_2168.JPG
 
Second attempt at timing it up correctly failed as well. Tomorrow will be my third time taking the whole thing apart and reattempting to get this thing done correctly before I call it quits and take it to a garage. I am now convinced (after extensive reading) that I have somehow managed to get the Fuel injector pump timing 180 out and it's not injecting fuel at the proper time. On the up side, I'm getting pretty good at disassembling the damn thing.
 
GuamBomb said:
So I went ahead and pulled the timing case cover off completely just to be sure I have every thing lined up correctly. I have the crank pin in and it is sitting at TDC per the mark on the crankshaft pulley. The FIP pin is in and its sitting at the 10 o'clock position. The camshaft timing mark is also in line with the arrow on the case. Here are some pics with the rocker cover off. Does this look correct?
View attachment 100619 View attachment 100620
Click to expand...
both the front valves should be fully shut ,both no4 valves partly open, is crank key at 12oclock with the pin in rear,have you removed front pump pulley nut or the 3 screws
 
GuamBomb said:
So I went ahead and pulled the timing case cover off completely just to be sure I have every thing lined up correctly. I have the crank pin in and it is sitting at TDC per the mark on the crankshaft pulley. The FIP pin is in and its sitting at the 10 o'clock position. The camshaft timing mark is also in line with the arrow on the case. Here are some pics with the rocker cover off. Does this look correct?
View attachment 100619 View attachment 100620
Click to expand...

Valves on no 1 don't look shut, as in partially depressed by the rockers.
 
Crank key is in and crank key is at 12 o'clock. I did not remove the front pump pulley nut but loosened the 3 screws when I put the belt on.
 
Valve is shut when the rocker on the the valve side is as high as it'll go and clear of the valve stem (like when you check clearances)
 
Last edited:
So if my valves on #1 cylinder are not shut. How do I get them aligned correctly if the crank pin is in the proper position and it is showing that I am at TDC?
 
Looks like I have some more reading to do before I tear into it tomorrow since I have never done either before. Thanks for all of the help thus far, I'll let you know how it turns out.
 
GuamBomb said:
So if my valves on #1 cylinder are not shut. How do I get them aligned correctly if the crank pin is in the proper position and it is showing that I am at TDC?
Click to expand...

The crankshaft turns through 2 revolutions for every 1 revolution of the camshaft.

The crank can be locked with the pin at tdc of the compression stroke AND exhaust stroke.

It's difficult to tell from the pics but you might be 180° of the cam (360° of crank) out.
 
You will have to excuse my ignorance on this...it my first timing belt change which is turning out to be quite the learning experience. So when you say turn the cam...do you mean turn the cam sprocket only? I've got it all apart again. Crankshaft is pinned at tdc. Do I remove belt and turn cam?
 
GuamBomb said:
You will have to excuse my ignorance on this...it my first timing belt change which is turning out to be quite the learning experience. So when you say turn the cam...do you mean turn the cam sprocket only? I've got it all apart again. Crankshaft is pinned at tdc. Do I remove belt and turn cam?
Click to expand...
you do if cam isnt correct whilst the other 2 are, cam should be correct if its dot is aligned,with the other 2 pinned but checking valves will verify that, and if not reason sought
 
Ok. I pulled the valve cover and pulled the #1 piston glow plug to feel when the compression stroke was occurring. All is lined up...crank pin in, 2 lines showing on flywheel through inspection port, valves on #1 cylinder appear to be closed, cam lined up with arrow, and pin through sprocket into FIP. Still no joy.
 
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