Timing out?

Hi I'm scratching my head here. I'v just changed the cylinder head on my1999 P38 2.5dt . I bought the timing tool kit and printed out the relevant workshop manual to do the job step by step. To cut a long story short ive got it back together and its running smoky and rattling like the cylinders are hitting the head. TIMING perhaps?. I've gone back and tried to set the timing 3 times and drawn a blank. I locked the crank with the tool and also took a photo to aid reassembly. I cant work it out. Am I missing something simple? Maybe I've got the wrong stroke at tdc? What do you think?

Almost certainly timing, being a mechanic is not quite as simple as some would think is it. Engine MUST be locked at TDC number one firing before head is removed. If the lock pin is removed with head off, the engine can be turned to clean piston crowns but MUST be turned clockwise only, TWO revolutions to return it to TDC number one firing on injection pump, then locked before cam is timed. You have a bit of work on your hands.

wammers said:

Almost certainly timing, being a mechanic is not quite as simple as some would think is it. Engine MUST be locked at TDC number one firing before head is removed. If the lock pin is removed with head off, the engine can be turned to clean piston crowns but MUST be turned clockwise only, TWO revolutions to return it to TDC number one firing on injection pump, then locked before cam is timed. You have a bit of work on your hands.

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I've cracked it! Dead right it was the timing. I ran out of skill at final hurdle. But its going now. Thanks for the help.

Jetski39590 said:

I've cracked it! Dead right it was the timing. I ran out of skill at final hurdle. But its going now. Thanks for the help.

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At least you will know next time. Well done.

That is very interesting and useful filed for future use, thanks wammers I can see that causeing a few problems.

brianp38dse said:

That is very interesting and useful filed for future use, thanks wammers I can see that causeing a few problems.

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Any engine that has that sort of work done should be turned two revolutions by hand to check for fouls before any attempt at starting it. Good practice and saves a lot of frustration.