AAZ IP / Pulley differences and IP install q's

[babba]

So I have an AAZ 1.9td from a 94 golf, previous owner told me the IP was "bad" (not leaking seals).  In the process of going into a mk1 rabbit...

So I went ahead and bought a (cheapest option, or so I thought) used IP, thinking any AAZ pump would bolt up.

The IP I received must be from a newer (guess, 97?) 1.9td...  because the sprocket and hub (pulley) is a totally different setup.

So basically, my old IP has a woodruff key in the pump shaft,

UNFORTUNATELY, I did not get and can't get a corresponding pulley with the new IP. The replacement IP (had) a "hub" compression fit to the shaft, and the body of the ip (near the 3 mounting bolts) does not appear to line up correctly with hole in the sheet metal "timing belt guard/cover"  (not the plastic cover but the piece of sheet metal that sits up against the engine).

(the older style IP is round where the pulley end meets the sheet metal, the newer style is larger with an extra bump out on the top)

Now, (this could have been a bad move, as far as ever getting the ip timed correctly)  but I pulled the piece that I earlier called a "hub" off the shaft of the replacement IP, and the inside shaft looks identical to the older style, with a cutout for a woodruff key, but the issue of bolting it up with the sheetmetal in the way still remains. 

QUESTIONS:
1) can I cut the sheet metal guard away to make this bolt up and then use the newer style IP with the old style pulley/key?
2) how do I line the marks/ etc up to tdc on the newer style pump.  Assuming this is different than the 1.6 that I am somewhat more familiar with.  Any relevant links would be appreciated.  I tried searching, no luck
3) Anyone have a newer style pulley (that will fit on the "hub" I have) for sale?  Assuming this would work?


-the piece I am calling a "hub" also has three bolt holes in it


-I will try to get pics, but it will be a few days.  Help or pointers in the right direction would be greatly appreciated in the meantime...


Thanks!

[burn_your_money]

I hate to say it but it's not going to be easy.

If you look at your `new` pump you will notice that where it mounts to the IP bracket is different. It has a 68mm mounting diameter where the old pump has a 50mm mounting diameter. You will also notice that your new pump does not have adjustment slots in the mounting holes for adjusting the timing. The pulley that bolts to the hub has the adjustments in it.

What you would need to do in order for that pump to work is to get the pump mounting bracket from a 68mm pump and also the pump pulley. Then you can swap it on. As for the timing backing plate, you will need to remove the captive nut off ot it and also enlarge the hole. It would be easier to get the backing plate from the 68mm pump.

By removing the hub you untimed the pump. There is a notch out of the hub and a hole at the top of the pump mounting area where you use a pin to lock the pump in position at TDC. If you do decide to use that pump it`s not a big deal to undo what you did.