Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - olderguy

Can anyone advise please. I have removed a Lucas diesel fuel injector pump - I have locked the engine at TDC as prescribed by the manual. I am puzzled by the pundits who suggest inserting 2 bolts through the fuel pump sprocket to 'lock the fuel pump in position' . When I took the pump off (what a pig). I then removed the centre nut and ended up with sprocket/flange bolted together BUT seperate from the pump - the keyway is obviously still there on the pump BUT surely any reconditioned pump will have been turned so how will I know that it is set up right? i.e my engine is at TDC and if it was running should be about to squirt fuel to No1 cylinder? Does ONE rotation of the pump = fuel to all cylinders? Help please!

Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - Peter.N.

One rotation of the pump will feed all cylinders as it is driven at half engine speed. You should have marked the position of the old pump before you removed it but its not difficult to set up.

Set it at about half way initially, it should start there, if its difficult to start, runs quietly and smokes, advance it by say 1/16" and try again. To advance turn it in the opposite direction to engine rotation or clockwise looking from the rear. If it knocks more loudly than usual it needs retarding a little.

I have just noticed that yours is a 2001 so will have some electronic control, the method I have outlined is for a purely mechanical pump but I think it should work.

Is it not possible to see where the original pump was fitted?

Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - olderguy

Thanks for the speedy response. I did mark all the places that seemed appropriate with dollops of white marker paint. I removed the old pump with the locking pin on the injector sprocket positioned at 2pm - which I've read is the place to find the fuel pump injector sprocket when No 1 cylinder is at TDC and the camshaft locking lug is at 4pm. Looks like a good idea to but the beggar back were I found it and press the button! Yes your right there does appear to be quite a lot of electrical connections. I'll go away now and source a pump and if it works at all (i'd settle for diesel being squirted initailly) I'll supply a response (if it don't work I'll pop up a scream for further assistance/assurance. Thanks again.

Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - olderguy

As promised a note as I now have the engine running. The original reason I removed the fuel pump was the engine failing to start and no apparent signs of diesel at the injectors. I now know the fuel pump was NOT 'faulty', 200 quid to prove it! Faulty immobiliser they (AF Jones Disel repair specialists in Manchester) said. OK that said when you remove the pump the timing belt comes off - hence you loose the pump timing BUT the pump has a built in static (for want of a better way of saying it setting) two timing holes (one a 12 o'clock the other 6 o'clock) I set it at 12 and with a hefty squirt of Easy start it is back to life (although it feels a little to crisp/rattly at the minute). Not sure as the whether I'm brave enough to shove the sprocket around to the 2pm where I'm sure it was when I took it off!

Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - Peter.N.

Pleased you have it running now, I have never known a pump to fail completely and I've been running diesels since 1959! It sounds as though its running a little advanced, we always used to adjust the timing by twisting the pump round on its mountings, you can do it with the engine running so you can adjust it until it sounds right, you usually have to jam a tyre lever down between the outlet pipes to get enough leverage. I have not had any experience with the semi electronic pump though all mine have been mechanical.

Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - olderguy

But that life was so easy! (to adjust timing that is by putting a tyre lever in) Nah my pump is bolted through from the sprocket side through the casing and into the pump body that in turn isn't slotted! There is some leeway by easing the three sprocket retaining bolts and then turning the sprocket on it's slot, that said it'll only give me about 5 degrees - but every little helps as they say, will try turning (effectively) the sprocket anti - clockwise (when viewed from the sprocket side) - this will move the pump flange at the back closer to my white paint dollop on the casing at 2pm. (when the engines at TDC) - The water pump has decided to leak now (no surprise there as you cannot lock the pump sprocket up when you take the pump off) and how the heck do you get the timing belt covers on - what a devil.

Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - Peter.N.

Oh dear, life used to be so much simpler. All the 1.9s I have had were mechanical as are my two 2.1td XMs which were both registered in Jan 96, must have been the last ones, one has done nearly 300k miles on the original pump without missing a beat. Presumably there is a procedure for setting yours up, if you have the timing cover off I suppose its not to difficult to do it trial and error, but you certainly can't do it while its running.

Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - olderguy

Success! The fork on the fuel pump sprocket & the rear flange aligning with the 12 o'clock timing mark in the fuel pump body (it's a 8mm hole pre drilled by Lucas) does provide the basic static injection setting. Fine adjustment is achieved by loosening the three 13mm sprocket retaining bolts and sliding/turning the rear flange clockwise (it retards the ignition) RESULT fires on 1st turn of the key once the glow plug light goes out! Even the water pump has stopped dripping - rejoice!

Peugeot 306 1.9 Diesel 2001 - Peugeot 306 - 306 Diesel Fuel Pump set up - Peter.N.

Well done, nothing like that feeling of 'how much would it have cost if a garage had done it'.