M-TDI no start after working on pump EDIT: Problem Solved!

[smokeinmirrors]

   Sorry, no build thread yet, but before the following happened, the car was running perfectly and had tons of power. . .

   This is an AHU engine with an 11mm Land Rover 300TDI pump (0 460 414 098).

   My pump developed a leak from the head o-ring, and somehow while changing the o-ring, (pump on car) I managed to break the plunger clean in half. Due to it being a gray-market pump, I was unable to find any parts specifically for it so ended up buying and installing a 2 468 334 060 rotor head assembly meant for an automatic transmission ALH pump.
   I have primed the pump and am getting fuel at the injectors, but the engine now will not start - It just turns over and shudders as though the pump is working but isn't quite building enough pressure. I had the fuel screw and throttle arm set exactly where I found them, but trying them at several different settings makes no difference. I wasn't able to take any good measurements of the old plunger, but holding them side to side, the new parts appeared to be the same as what I took off with the only noticeable difference being slightly smaller holes in the new plunger.

    Any ideas on this? At this point i'm considering chalking this pump up as a loss, and just buying another one from the U.K. to get the car back on the road.
Thanks for any input,
Kevin

[8v-of-fury]

If you just put the 11mm plunger from the ALH in the 11mm head from the rover pump you may have the issue there.

Those are a machined pair, and they wear together. I think if you mix and match parts it causes issues.

If you installed the whole head, then I dunno.. lol

Have you tried with your foot down on the pedal? This can mimic more fuel screw or more idle set screw and at least get it running so you know you are then close. Try starting it with the foot down a bit and see if you can get it to fire off and hold an idle with your foot. If you can, then you just need to bump your settings up a bit.

[libbydiesel]

The shim at the base of the plunger can make a big difference in overall fueling. 

[smokeinmirrors]

Definately replaced the head and rotor together, and full throttle made no difference for me unfortunately. I'm guessing that to increase fuel pressure I just need to install the largest possible shim that still leaves clearance from the timing plug right? I went ahead and ordered another Rover pump from Ebay as a backup today, but I would still like to get the one I have sorted.

[smokeinmirrors]

Turns out I had the camplate installed 180 degrees off - I had subconsciously assumed that it could go both ways during the initial assembly.  Switched it around and the car is now back to it's old self!