Timing

[Surfboy]

Can someone help with this please?

I am struggling with the timing. I set the cam to line up on the 12 oclock mark but I can't turn the crank far enough so that the crank and pump are lined up.

I had it so that the crank and cam lined up but the pump was way off.

Is there a step by step process assuming all parts are out of time?

The crank and pump are internally timed aren't they? I just can't marry them all up (by the way, I've never done it before haha! )

[will.b]

Timing

Turn the crankshaft another 360 degrees. They only all line up every 2 revolutions. Once they are all lined up then you can remove belt and tensioner to replace them. Do not move anything until new belt is in place.

[Surfboy]

It may be me being a plonker but I can't seem to get the crank to go through a whole 360 degrees. It goes so far either way relatively easily, but I am afraid to give it too much leverage on the bar.

[BUSHWHACKER]

How far and in which direction have you turned the crank and why?

The crank shouldn't need to be touched when changing the pump or belt if the marks were aligned BEFORE removing the belt.

[Surfboy]

How far and in which direction have you turned the crank and why?

The crank shouldn't need to be touched when changing the pump or belt if the marks were aligned BEFORE removing the belt.

To be honest, in the whole process of fiddling, I can't be sure how much has moved and in what direction!

That's why I was wondering if there was a step by step process from it being out of alignment

[Dobbslc]

If you've got the belt off already you could be clashing valves and pistons. DON'T force the crank round! Try to remember what way you turned things and carefully turn them back again. On the 3.0 the pump turns with the crank so that should be ok.
If the belt is still in place turn it clockwise(I think) slowly, you will feel one of the pistons coming up to compression and it will be harder to turn, just hold it in this position for a few seconds and it should get easier to turn as the compressed air leaks past the rings. You might need to turn it 360° to get the marks to line up.
If it feels like it's locked solid (metal to metal) then the timing has gone out and you might have damaged something. STOP! And consult someone that know's the engine type.
Hope this helps.

[BUSHWHACKER]

To be honest, in the whole process of fiddling, I can't be sure how much has moved and in what direction!

That's why I was wondering if there was a step by step process from it being out of alignment

If the crank 'feels' locked and can't be rotated any further clockwise, turn it anti-clockwise 'till the timing mark lines up.
Would be a good idea to remove number one glowplug (nearest radiator) as well to check when the piston is at TDC, (top of it's upward stroke) when it is, the crank timing marks should line up.

I doubt you would have rotated the crank a full 360 degrees during your fiddling, more likely gone past the timing mark clockwise rather than anti-clockwise.

[Surfboy]

OK after a little manipulation with the timing belt on and off, I have lined up all three marks. Pulled the pin out of the tensioner and have done a full 360 degrees turn of the crank. It all still lines up!

Time to reassemble everything now. Job for Friday evening if it's dry or over the weekend.

Light at the end of the tunnel at last!

[Surfboy]

All reassembled and I haven't got any bits left over. Good so far.

After charging the battery, I reconnected it and tried turning it over. The glow plugs light up as usual but it's just turning over and over. No sign of fuel being ignited.

What's the best process of elimination? I suppose I need to check that fuel is being delivered to the injectors first?

[BUSHWHACKER]

The fuel system is generally self priming, but yours is a little er, modified due to the extra long fuel hoses and filter etc.
There's probably a lot of air in the pipes so it'll take a while for the pump to build enough pressure to squirt the injectors.

Keep charging that battery!

[Surfboy]

Well had another go with the battery charged up again. No sign of it firing at all. I would expect a splutter, but nowt! Turned it over until the battery was flat again. It's now charging again but it must be something else.