TDi timing nightmare

[Doctle Odd]

I bought an old octavia couple of weeks ago. Today I decided to change the timing belt. I put the flywheel on TDC and the locking bar fitted perfectly into the cam. However ... the pump was about 180 degrees off. Anyway I took off the belt put the locking pin into the pump and fitted a new belt. Now the car wont start. Any suggestions? Could the cam be 180 degrees off? I've changed a few dozen of these belts and I never seen this before. Thanks

[zollaf]

the cam timing slot is offset so can only go one way round. the flywheel mark can't be anywhere else, so the problem must be the pump. could it have the wrong pipes on it going to the wrong injectors, thus needing to be 180 out ? thats all i can think of, unless its the wrong pump or has been rebuilt wrong. whatever has happened, the last person to do a belt must have known about it to get it out by 180 yet for it to run perfectly.

[Doctle Odd]

Thanks Zollaf. The pulleys and backplate were covered in tipex marks that I cleverly cleaned off. I'll have a look at the pipes but I'm pretty sure they cant be fitted wrong but am open to correction. The last owner only had it 3 months just drove the tax out.

[zollaf]

the only other thing is if the pulley hub was removed from the pump as its not on a keyway. they may have then just kept adjusting the timing until it ran. if i had a known good pump then i would swop them over , or failing that take this one to a diesel shop to get the timing set, unless you know how to do it, which i don't. i have known this happen where instead of just undoing the 3 bolts holding the pulley on, someone undoes the central hub nut, then is all lost when there is no keyway. i bet thats what has happened.

[Doctle Odd]

You could be right Z. I think a trip to the breakers is in order. I could probably get her to run by putting the pump back and use trial and error but it's pretty pointless. A new pump would probably cost more than she is worth. Would any pump fit her or does it have to be AGR?

[Rob69]

Good few years since I did an old tdi belt, but it sounds like previous owner changed the pump with flywheel 360 deg out and didnt use cam locking bar, hence the tippex marks. Can you set engine to tdc no4 firing, ie cam shaft 180 deg out, no1 cyl valves on the rock, and reset pump with locking pin. Pump pulley sounds like its been fitted 180 deg out relativ e to pump shaft/rotor. You'll need to remark cam pulley with tippex and get crank marks spot on before slackening belt. Injector pipes are not long or flexi enough to be fitted to compensate for pump being 180deg out.

[Doctle Odd]

Good few years since I did an old tdi belt, but it sounds like previous owner changed the pump with flywheel 360 deg out and didnt use cam locking bar, hence the tippex marks. Can you set engine to tdc no4 firing, ie cam shaft 180 deg out, no1 cyl valves on the rock, and reset pump with locking pin. Pump pulley sounds like its been fitted 180 deg out relativ e to pump shaft/rotor. You'll need to remark cam pulley with tippex and get crank marks spot on before slackening belt. Injector pipes are not long or flexi enough to be fitted to compensate for pump being 180deg out.

The cam and flywheel marks lines up perfectly when I was putting her in the reference position.The pulley on these has no bearing on the setting as you need to replace the bolts when you change the belt. The notch on the pump is 180 degrees off the setting hole. The car ran very well doing over 60 MPG so I'm thinking the pump itself is ok. I have borrowed a Vectra (no sniggering at the back) and today I will take the pump to a diesel specialist. He should be able to check if it's timed correctly or not.

[Doctle Odd]

Thanks to anyone that replied, the pump centre nut had been loosened and the factory settings lost. Pump is back to factory settings now for the next problem....