Lucas to bosch swap; timing out?

[shonkers]

Hi all, i,ve just started the pump swap on my p reg 406 2.1 td and it appears the timing is out, the cam and the pump holes line up but the flywheel is about 6 teeth/ 2 inches out, i can,t think why because i changed the pump (lucas for lucas) i know, why you ask, everything lined up when i did it and it started first time and ran sweet as a nut for a couple of years. Then it struggled to start but once running fine, so had it checked at pug dealers in ibiza, they said pump knackered, anyway drove it back to blighty no probs apart from poor starting. I,m loathe to make my own marks and set it as it is and would like to do it properly, any ideas?

[jasper5]

If you haven't removed the timing belt yet I would do it this way...

Mark the flywheel in the position that it is right now so that you have a point to refer to.
Mark the cam pulley teeth and the teeth on the injection pump.
Screw in the locking bolts on the cam and injection pump....mark where the injection pump keyway is positioned and check the new pump keyway is in the same place when you fit it and screw in the locking bolts.

When you fit the new pump move the flywheel until the locking pin can be inserted but leave the cam and injection pump locking bolts in.
Fit the timing belt and remove all locking bolts and flywheel locking pin.
Turn the engine over very slowly a couple of times and check for any resistance...if all feels good then try to start the engine.

If you have any problems then lock the cam and pump in position and move the flywheel back where it was before you removed the timing belt and turn the engine slowly a couple of times again...then see how it goes

[shonkers]

Thanks for your input jasper5 that makes sense in case i get mixed up, but im still trying to figure out this can be and still run ok an pass mot emissions etc before i started job, i,ll double check everything and do what you suggest so at least i,ve got a base line, has anyone else had something like this

[shonkers]

It looks like the aux drive had a rib sliced off prob about a foot long and somehow made its way into the timing belt causing the crank to jump a tooth, i,ve an idea the drive belt tensioner is knacked,so thats going to be changed in fact i,m going to do the lot waterpump and timing belt kitand aux drive belt kit, i found prices pretty cheap with mister auto who use their own brand called bolk, they're based in germany but not sure of quality of this bolk brand, i recently fitted a waterpump and timing belt to my nissan serena with no issues but only time will tell. Has anyone else used bolk before and what do they think. Also once all this is done it may turn out that the pump is alright, i,ll soon know come start up. I know someone will say i should carry on an change the pumpanyway while everything's out the way cos now is the time to do it

[shonkers]

Heres an up date the timing was out the belt jumped a tooth on the crank caused by a portion of the aux drive belt findind it,s way into the timing belt covers, which in turn was caused by a worn tensioner, i fitted a new timing belt kit and reset the timing to what it should be. I couldn't change the water pump because two bolts felt like they were going to snap so i left well alone i,m hoping it wont need changing any time soon, then i fitted new aux drive belt kit and it fired up first turn of the key happy days, i,ll keep the bosch pump until the lucas gives up the ghost thanks for everyones help and advice

[Doggy]

Good result, well done.