XUD9 Timing - again

[xsaras4ever]

Hello to all.

We have finished putting the Citroen ZX 1.9d engine into our Peugeot Boxer. Plenty of work it was. Apart from changing the engine you have to change the flywheel and the sump and the oil-pan on the oilpump also. Also , the boxer has a remote diesel filter so the housing for the diesel heating system needs to be changed too. Also the engine mountigs are different.

Anyway.

We bled the injectors and fired it up.

It popped a bit and then ran.

It runs un-evenly and smokes and tries to eventually die - its better if you rev it.

We trust the seller of the engine so instead we suspected the timing.

At this point we should mention that we swapped over the injection pump from the previous engine - an engine that had sucked its oil and run at mega revs - we stopped it before it exploded.

Unfortunately we forgot to mark the pump against the aluminium casing that it sits in so we gave it a best-guess effort based on the marks that the washers left on the casing.

We have re-checked the timing and it is spot on.

When we crack open an injector it runs a bit better (still uneven) and worse when you close the injector. Same with and of the 4 injectors so its not an injector problem.

Must be an injection pump timing issue.

We are being lazy here - do we move the pump closer to the block or farther away - based on our symptoms ?

Moving the pump will mean refitting the timing belt as either way we either gain or lose a tooth - so we are trying to avoid doing it twice.....

Thanks in advance

[wheeler]

If you are wanting to adjust the pump timing there should be no need to disturb the timing belt.
You slacken the pump mounting nuts & rotate the pump on the elongated mounting holes in the pump.
To do it properly you need a DTI that screws into the back of the pump but you can do it by trial & error just moving the pump a little bit at a time.
Or am I missing what you are trying to do here?

[xsaras4ever]

Thanks Wheeler, did exactly that and now it runs fine.
It just passed its emissions for CT with flying colours.

Didn't have a tool, hope its all ok (in the long term)

[Pug_XUD_KeenAmateur]

not sure if the Pump Timing will be same between an XUD 1.9na and a 1.9TD, but I've always based my calculations on being able to get a 6.5mm Drill bit beneath the forward lower mounting (the easiest one to reach).

[kenbw2]

A 1.9D N/A in a Boxer, that must be rough. I have a hard enough time with the 1.9D in my Dispatch.

[Barney00731102012]

I’ve just rebuilt my Peugeot Boxer 1.9td 2001 engine. Fitted brand new complete cylinder head, 4x new diesel injectors, secondhand EGR valve as I couldn’t source a new one anywhere, bottom end honed out bores and new piston rings and bearings, new intercooler. Anyway fired it up smoked like mad, ( black smoke). So checked all hoses fitted a new air filter, fuel filter. Still no joy. Anyway saw this post and thought I’d adjust the pump timing with the 6.5mm drill under the pump bolt.Definitely and massive improvement.I thought as we are off on a three month road trip I’d book it in a diesel specialist and get it double checked. So I did some research and found a specialist 30 miles away who have really good reviews especially as I don’t have a lot of faith in garages and certainly after working in the motor trade for 20 years. Got it back three days late with a £700 bill. Saying they have removed the fuel pump checked and tested it and had pretty much cured the smoking. Today I did an oil change and noticed the diesel pump had been put back to where it was before I put the 6.5 mm drill in. The smoking doesn’t seem to be a lot better than when I dropped it off. And I certainly don’t think now the diesel pump has been removed and if it has they haven’t fitted anew timing belt ( very worrying) the tell tell time will be this week when it’s Moted with the diesel emissions.