Injection pump timing

[PZ LC]

I just had my IP rebuilt on my 1PZ.

I ordered the special tool and trying to get it timed correctly. The plunger stroke for the 1PZ is 0.82 - 0.88.

To achieve.0.85mm I'm having to set the pump advanced far enough that I'm running to the limit of the adjustment in the slotted holes in the pump (clocked toward the engine)

I've checked and recheck dozens of times. All the timing marks line up prefecture at TDC.

I'm concerned that the pump is too far advanced but stoke length measures to spec.

Is there something I could be overlooking?

Hopefully I've explained clearly

Thanks in advance

 

[Eurasiaoverland]

Are you sure all your timing gears are correctly aligned?

If you are sure the belt has not slipped a tooth one the pulley, I would send the pump back to the diesel workshop and ask them to check, though I can't see how static pump timing could be so severely off in the pump internals.

 

[PZ LC]

Yes I'm certain they are all aligned at TDC. The marks are obvious. And I am aware thay there are separate marks for BDC for setting up the timing belt.

I could take it back but unfortunately I live fairly remote so it would be 2 ferries and almost an all day affair to go back so im.hoping to solve this at home.

 

[Eurasiaoverland]

With the plunger stroke at 0.85 mm, what do the matchmarks on the side of the pump/rear timing cover look like?

I would give the shop a call at least. Ask what they replaced. Did they re-shim the plunger?

You say you have done this multiple times, that should eliminate any chance of having the DTI incorrectly mounted to the cantilever tool.

 

[HZJ75 FARMER]

Are you turning the engine the correct direction?

 

[PZ LC]

Well, I got it sorted. I'm not exactly sure where my problem was but I suspect it may have been with tool setup as you suggested. That night I decided to put down the tools and, pick up a beer and revisit the next day.

I removed the tool and gauge, restarted the procedure from step one. Aligned all the timing marks including the one on the injection pump with the casting on the block. This time the stroke was nearly perfect. A slight adjustment before buttoning back up. Runs great.

A good reminder that sometimes the best procedure to follow is to step back, and start again from step one.

Cheers @Eurasiaoverland for your input!

With the plunger stroke at 0.85 mm, what do the matchmarks on the side of the pump/rear timing cover look like?

I would give the shop a call at least. Ask what they replaced. Did they re-shim the plunger?

You say you have done this multiple times, that should eliminate any chance of having the DTI incorrectly mounted to the cantilever tool.

 

[PZ LC]

Another question if you dont mind.

After reinstall, my timing belt is running a little of center of my pulley which I don't love. I centered it all up before starting and as soon as the engine runs it shifts over that couple mms.

The belt and tensioner are about 18 months old and roughly 18 000 kms on them, Toyota parts.

I removed the belt again,I removed the pulley from the injection pump and made sure all the surfaces were clean and retorqued the 4 bolts holding it. There is zero play in the tensioner.

The one concern i have is that when I used the puller to push the pump shaft out of the gear it took extreme force to pop it out of the tapered gear. It actually pulled the gear forward slightly when it popped. It tapped back into place with a light tap. Could I have misaligned something at this step when I was removing the IP?

Any thoughts on this?

 

[Eurasiaoverland]

Great that you sorted it. 100% with you that stopping for an evening and starting fresh the next day can solve these minor mistakes. Too many times I have dug myself a bigger hole by not knowing when to call it a day.

Regarding the timing belt, it looks fine to me. The belt will find its own place to run. As long as the keyway in the pump shaft and pulley are perfect, I don't see any scope for damage. Can you run the engine with the timing belt cover off and watch the pulleys? So long as they run true, I would get it back together and run it.

 

[PZ LC]

Thanks @Eurasiaoverland I really appreciate it.