w210e55amg

So I recently purchased a 1987 300d turbo that needed work. The previous owner told me that he had brought it to a shop that "fixed" a dv leak. But in doing so they mis-aligned the calibration barrel. I removed the injection pump following the correct procedure. Sent it to the nearest Bosch injection pump specialist he reported that the alignment pin for the 1st cylinder was bent and he had to disassemble the pump and replace, then calibrate it. $700 later I got the pump back, checked and double checked the timing on the crank (verified accuracy by checking with the camshaft) before re-installing injection pump at 15 deg atdc. Took a little cranking to bleed air from the lines but it will only start when pedal is near the floor and it surges from 500-1200 rpm while puffing an extreme amount of smoke. So I've checked and re-checked timing by looking at the reference port. Everything seems to be in order, I do realize that it would be best to use an a/b light to fine tune the timing but shouldn't it run reasonably well? Is there anything that I'm missing? Could the pump be incorrectly calibrated? Should I bring the car to a specialist to have the timing dialed in using the best tool for the job? I'm just stuck and looking for some advice to what I should do next. Thanks for any help that you can offer!

GregMN

The timing is not that sensitive. If you had the pump locked properly, and the crank timing set at 15 degrees after TDC ( not ahead of TDC), then it should run reasonably good.

If you set the crank at 15 ATDC and look in the timing mark viewing port, the timing ridge should be in the center of the viewing port.