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Discussion Starter #1
Hi all, ok here goes.....
My 08 807 2.0 hdi had a worn fuel pump key which eventually broke the end off the camshaft.
After getting a new one the timing was locked, engine split and the broken camshaft removed and replaced. After everything was rebuilt and the timing unlocked we bleading the fuel system and tried to start it with no joy.
While trying to start it the engine went from turning over normally to "skipping" as if out of sequence.
We realigned the timing and locked with pins to discover that although the cam and under-starter pins were locked in place, the marks I made on the flywheel now seem to be out by 1 tooth. Not sure how this can be if the pins are lining up.
I'm at a loss and am contemplating replacing the engine.
Can anyone offer any help??? Cheers
 

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The chain has marks on it to align properly and it can move while refitting are you sure its correct

Dont make your own marks use the pins this avoids confusion the pin holes cannot move !

Is your replacement cam new or used as if used it may have come from an engine where the belt has gone and sometimes the chain gears move !
 

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Discussion Starter #3
Thanks for your reply. With the pins in we replaced cam with new cam. I also marked the flywheel as an extra precaution. The pins still line up perfect but the flywheel mark is out.
Do you think my problem is at the chain, maybe one of the cams is a tooth out?
Thanks , it's an 8 seater which I'm desperate to get back on the road...big family
 

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As i say dont make your own marks there is no need the pins in are all you need the 2 cams must be correct i know by looking as i have done so many over the years but it is easy to get 1 link out but it would still start just run badly more than 1 i doubt it would run

Your still not clear was the cam new or a used one ?

Do you have the crank sensor back on and the ring for it on the bottom pulley and do you have access to something to read live data while cranking

lots of questions but if i get all the answers we get to a conclusion quicker.
 

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Discussion Starter #5
We replaced the camshaft with a new one. Crankshaft sensor and ring refitted on the bottom pulley although there seemed to be a bit of play on the rear timing belt pulley.
I did have a mate plug it in but his didn't read live data. The only fault it showed was glow circuit relay opening when not instructed to.
Hope this is of some help. Cheers
 

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Bottom pulley is designed to be loose to allow for timing belt to tension fully it has an ellongated slot the belt is tensioned then the pulley is tightened

My next step would be live data to see cranking speed cam and crank sync and fuel pressure if these seem ok then you might need to go in again and check cams are timed correctly.

Sometimes they need a bit of help to start after rebuild IE a tow but i would want to be sure timing is right first
 

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Discussion Starter #7
Thanks for all your help on this. I'll pop the cover off and check the chain & marks and I'll get it plugged in to check the live data.
Ill let you know how I get on. Thanks again
 

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Discussion Starter #8
Hello again. I had another look last at the chain timing. I have attached the diagram my mechanic friend used to reference the timing. Does this look accurate to you? I have done a bit of searching myself and can't seen to find one specifically for the rhk engine. Thanks again
 

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