New timing belt, smoke.

[mayon]

I fitted a new timing belt to my 98 vg 2.5td with Bosch injector pump, I had to loosen the 4 bolts on the pump pulley to get the belt on. Fitted the three pins and wound the motor over twice by hand refitted pins, put it back together. What I noticed when starting it up was it seemed quieter than before and was idling a bit higher, when I went for a drive it was blowing black smoke which I hadn't noticed before. I backed of the fuel mixture screw on the back of the pump a bit and now its blowing grey smoke. Any thoughts, thanks.

[meerkatmag]

You've adjusted the timing of the pump. With the 4 bolts loosened you can rotate the pump to advance/retard the engine. Sounds like you did this by mistake and it's now retarded. You'll need to get the cover off again and adjust pump timing.

[MinorMatt]

Bosch pump on a TD engine needs the timing to be artificially advanced (i.e. the pin shouldn't go in)

[mayon]

Thanks for the replies, I have taken the front of and tried to advance the timing, but I only moved it a degree or two and came to the end of elongations in the pump pulley. All the pins still fit in, I could take the belt of and move it around a tooth but in the Haines manual it says wonce you take the tension of the belt it has to be replaced. I am thinking of just putting it back together as it is and ordering a new belt if necessary.

[meerkatmag]

I think minormatt means you need to advance it beyond the pin position. So you'll have to remove the pin from the pump and rotate the pump clockwise slightly further. Then tighten bolts. Perhaps wait for minorMatt to explain as he's way more experienced than me.

[mayon]

I can't advance it anymore because the bolts are at the end of the elongations in the injector pump pulley.

[meerkatmag]

It sounds like your pump is not timed correctly to the front pulley. This has to be done with a dial guage. Unless something else is wrong. Did it improve things at all when you advanced all the way?

[cherniy_chack]

It is necessary to determine what mistake was made when replacing the belt - the injection moment became earlier or, on the contrary, became later than optimal.
If it is impossible to set an earlier injection/earlier synchronization without reinstalling the belt, then loosen these four bolts and turn the pump shaft by the nut counterclockwise to about the middle of the slots in the pulley.
Tighten the bolts, start the engine and make a test drive.

[mayon]

Thanks for the replies, I think the mistake I made was when I put the injector pump pulley back on it wasn't centered in the middle of the slots. As it is all the pins fit in but I can't advance it anymore because I have come to the end of the slots. It drives ok but blows smoke when you put your foot down, I have ordered a new timing belt and will do it again making sure there is room for adjustment.

[meerkatmag]

Thanks for the replies, I think the mistake I made was when I put the injector pump pulley back on it wasn't centered in the middle of the slots. As it is all the pins fit in but I can't advance it anymore because I have come to the end of the slots. It drives ok but blows smoke when you put your foot down, I have ordered a new timing belt and will do it again making sure there is room for adjustment.

Right, yes so essentially the belt is in the wrong tooth. Next time you don't have to remove the pulley, just loosen the bolts and it moves enough to get the belt on. Have you taken belt off and put pulley back in the right spot?

[mayon]

Yes it's on the wrong tooth, I had taken the injector pump out to access the fuel solenoid which is under the rear mount. The Haines manual says once you take the tension of the belt it has to be replaced.