As Martin mentioned...installing the IDI camplate with a
12mm head will bring the motor up close to stock TDI power (but with more smoke as Martin mentioned)...but it is not a fix all. To address the problem properly, the pump and its internal pumps should be setup for a DI engine.
As for which part the control lever is...
I'd suggest maybe looking into someone to help you in building this pump, especially if you aren't familar with the internals of the pumps themselves. You def. want to be familar with the internals of the pump. It depends on your comfort level though.
On the timing of the motor itself. Honestly, unless you have ALOT of experience and are super precise, I can't think of good honest ways to time the motor (that I'd feel secure with) without tools.
There are a couple reference marks. For one...you set TDC using the flywheel pointer...align that to the reference mark in the tranny bellhousing...
The camshaft SHOULD get locked into position at TDC...in this position the cam lobes on cylinder 1 are both pointed up. Then a locking plate (which can be simply made from some steel bar stock) is inserted in the end of the cam...if you have the valve cover off, you can easily see where this sits.
The IP pump, especially if you are using an old IDI pump and sprocket also has reference parts. At TDC you align the small slot of the sprocket on the back to the reference notch on the front body of the injection pump
I can't find a good picture of that right now...
From there, you can then use a DEEP WELL 13mm socket (or there is a special tool) to lock the injection pump in place.
At that point, the engine would be ready to set and tension the timing belt (the brief version), the biggest thing to worry about is when tensioning the belt about the crankshaft moving and setting you off a notch or so...which is easy to do. If you don't have the tooling to keep the other things in check (and time) then you have 3 things to worry about moving.
After that, you can then walk through doing the actually setting of the injection pump timing via the use the the dial indicator in the back of the pump and rotating the injection pump body relative to what the gauge says you need (AFTER being set to those initial timing marks above).
Rotating the injection pump itself as an entire assembly (with loose timing belt) is not the way to go and is just asking for trouble in the end.
I'd suggest a set of timing tools...they aren't too expensive and the need to have the bentley next to you...which does walk you quite nicely through the process. Its alot better than a toasted motor in the end to be perfectly honest.
Joe
Topic: mTDI no power.... (Read 11299 times)
