Been doing a tdi conversion in my 109 and I cannot get it to start. I have bled the filter and the injector pump several times and the injectors several times.
I took out a glow plug and corresponding injector and it was injecting fuel at the wrong time. So thought the timing was 180 degrees out so re did my timing and put it back together and still no start not even a cough. The engine started and ran nicely in th discovery it was removed from.
I used all the correct timing tools. The fuel pulses out of the injector pipes as they should. The battery was fully charged but it still shows no signs of starting. It turns over nice and quick and the lift pump pumps well. The stop solenoid is definitely working I've done the click test and had a feed coming off a separate battery just in case. Any one have any other suggestions?

if you are sure the timing is correct, and the fuel solenoid works, then it's probably fuel related.

you stuck the fuel pipes on the right way around? cracked the injector nuts until fuel comes out? tried giving it a bit of squirty?

Everything but squirting magic juice in it. Which id rather avoid if possible. Just to confirm the injector pump timing should always be at the 11 o clock position for the locking tool to fit in the slot. I have tried it in both 11 o clock and then 180 degrees round at about 5 o clock and still nothing not even a cough. The crank and the cam is perfectly aligned using all the locking tools to lock into place and having the rocker cover off to double check TDC. and it's perfect. I've pumped fuel out of every banjo and injector possible.

Does the fuel system have to be completely sealed? I only ask because my lift pump allows diesel to drain back into the tank and so I've disconnected the feed from the tank to the lift pump and replaced it using a bottle to keep pressure.
Could this likely cause any problems?

109inches said:

Everything but squirting magic juice in it. Which id rather avoid if possible. Just to confirm the injector pump timing should always be at the 11 o clock position for the locking tool to fit in the slot. I have tried it in both 11 o clock and then 180 degrees round at about 5 o clock and still nothing not even a cough. The crank and the cam is perfectly aligned using all the locking tools to lock into place and having the rocker cover off to double check TDC. and it's perfect. I've pumped fuel out of every banjo and injector possible.

Does the fuel system have to be completely sealed? I only ask because my lift pump allows diesel to drain back into the tank and so I've disconnected the feed from the tank to the lift pump and replaced it using a bottle to keep pressure.
Could this likely cause any problems?

Click to expand...

it should still cough.

you checked it's chucking fuel out the back of the exhaust? i'd give it a squirt, does no harm.

I think there is one engine model (not sure which one though) that has two notches in the flywheel and it is possible to try and time it on the wrong notch. To confirm you have TDC correct the woodruff key in the crank pulley should be vertically upwards, then make sure the timing pin goes into the bell housing and into the correct notch. Then you can check the cam and FIP timing.

Did you do anything to the engine between removing from the doner and installing it? and when you checked the timing did you actually adjust anything? No reason for timing etc to move or change just because you remove / install the engine.

all sorted completely redid the timing and started by barely touching the key and no glow plugs needed either. So very happy. Can finally start putting it back and getting back to looking like my Land Rover again.
Turns out my injector pump locking tool was slightly wider than it should have been. Meaning I could never find the slot it locks into. So I was at about 9-10 o clock position when the correct placement is around the 11 o clock mark.

Kwakerman mine does have the two notches on the flywheel but followed the trailer fitters tool box tutorial which explains which notch to use. Once the timing was correct barely touched the key. Second tdi engine I've not started in almost a year and just starts up like it was used a few hours ago.
Thanks for the help guys