Timing belt issue..

[ArozNick]

Evening guys,

Needing some of your advice again!
So my timing belt due on my DW8B engine, first time I have changed it on this engine,

Unfortunately the engine which I have seems to be a miss mash between a 1.9d and a 2.0HDI. It's a 56 plate and i believe they stopped the DW8 in late 2006? Anyway.

Somethings not quite with the timing, I manually turned over the crank before starting it to make sure, and it turned fine. Unfortunately it's very, very loud compered to before. Nor does it start the first turn of the key (Which it did do before)

The cam sprocket was locked, and the teeth were tippex. Same goes for the Fuel injection pump, and the flywheel. 

The cam sprocket is fixed with a single bolt, where the fuel injection pump has the main centre bolt, and 3 smaller bolts with elongated holes I believed. either way, non of these were moved.

My only thought is that when I removed the crankshaft pulley, it sits on the crankshaft sprocket which has a woodruff key to locate it, although the actual hole which locates the woodruff key itself seems to be larger than the actual key. This may have moved from the right side of the hole to left side, which is about 1/2-1 tooth. Would this cause the issue?

I have tried to give you all as much information as possible... sorry if a lot of this may not make sense.
I will try to upload a short video soon.

Thankyou

[cancunia]

The DW8B is the 1.9 engine? The 2.0 engine has a keyway which is wider than the key, I think this is to allow a bit of movement when getting the belt on. There are a few videos about this that may give you some ideas, or there will be some threads about it on here.

[brodfather11]

The crankshaft pulley does not have anything to do with the timing belt, its something to remove when fitting a new belt. It drives the fan/auxiliary belt etc. Position is not critical.

If the injection pump timing is out then the engine can make very loud and alarming noises.
With the DW8B it should have electronic injection timing.

On a DW8/XUD the crankshaft and camshaft should be locked/pinned with the adjuster loose and the pump pulley free to turn.  The adjuster is set then the pump pulley tightened. Turn over by hand then recheck timing pin holes and belt tension.
Redo if needed 

If the pump pulley was not loosened enough to allow the pulley to move by the three bolts then its not done right.

Throw away the tippex its not needed to do it right.

[Kieron G]

Apologies if I'm going over what has already been said. The flywheel should be pinned to lock the crank and the fuel pump and cam pinned through the pulley. The three set screws that allow the fuel pump and cam pulley to move slackened a bit and according to Haynes from memory they are rotated clockwise as far as they go. I found going this far would put it a tooth out. I was happy when after fitting new belt I could see from the bolt marks on the pulley faces that they ended up in almost if not exactly exactly the same place.

[ArozNick]

The DW8B is the 1.9 engine? The 2.0 engine has a keyway which is wider than the key, I think this is to allow a bit of movement when getting the belt on. There are a few videos about this that may give you some ideas, or there will be some threads about it on here.

Yup, this is what I'm saying... It makes no sense when it's the DW8B engine. :/

The cam sprocket is fixed with no 3 elongated bolts.
The pump pulley does have 3 elongated bolts.
and the crank sprocket is the one with the woodruff key.

Cam sprocket, pump, and fly wheel were locked. (For the people saying that I need to lock them...)

Unfortunately I'm out of time on getting this sorted myself now, going to take it to my local mechanic 5 miles down the road. Like I said, it starts just sounds very rough and tappy. Think it would be safe to slowly coach it to the garage?