Stretch did an exhaustive posting on the vacuum pump and timing device, with loads of good pics here:
http://www.peachparts.com/shopforum/diesel-discussion/339870-more-than-you-likely-ever-want-know-about-om61x-piston-vacuum-pumps.html
Some good pics of the timing device in bits, the IP drive shaft, etc.
"The other day I decided to check that I had installed the inj pump correctly - I found that the timing was out!"
The first thing to do is to re-set the IP.
Which kit did you use to rebuild the lift pump? There is a complete rebuild kit.
If there is very little coming from the IP, it is probably out of sync. Reset the IP and try again. If you didn't use an IP lock when you stuck it in, it could have moved out of the place you set it at as you slid it in. Remember these inline IP's are like small engines- there are cams and everything- and getting it set on mine, it had to sit at a position where is could easily have been disturbed, causing it to rotate off one of the cams.
"It is a NA motor with an aftermarket turbo"
This is very interesting. You upgraded the pistons to turbo type as well?
You have mentioned a lot of changes made to his engine. This tends to multiply exponentially the problems while trying to get it back together. Did this engine ever run properly without the addition of the aftermarket turbo?
I am thinking this may be a short-lived venture. Replacement turbo pistons are hard to find, and cost at least 6 times the price of the NA types. Piston cooling nozzles installed? The pistons can get hot in a turbo without them! Plenty hot enough to fail. I cast aluminum parts- I pour usually around 1350°F- quite close to some turbo exhaust gas temperatures. The internal temperature when the cylinder fires is even higher! And before aluminum is at pouring temperature, it has already failed structurally.
Let's at least track down this "fueling" problem and get it running properly. Then we can look into the "aftermarket turbo". You may want to call it an "after-burner."
snapped_bolt