AAZ knocking/timing

[Big Daddy Roth]

I did a aaz swap into my syncro passat. I used the G60 flywheel. Are the TDC marks in the same position??

I have knocking at 'mid-throttle' conditions. I either have to be into the pedal or off of it to achieve no knocking. Cruising is annoying.

I have a giles pump set at .92mm (or at least I think it is). It made similar knocking at .80mm and 0.85mm. I suspect it's my injectors. Time for fresh nozzles?

[R.O.R-2.0]

make sure that the TDC mark is indeed at 0*... some VW wheels were not marked besides like 6* or 8* advanced.. my car made the weird knocking too, until i switched to a diesel flywheel again..

[blackdogvan]

Tho g60 FW is a known upgrade so its likely not the problem ror. I would think confirming TDC & double checking your cam timing would be the best bet first?

I've been lurking on dubberz & watching your syncro build there btw, looks great.

Juuuust figured out who you are btw... thanks for the merc dual horns!
Reuben

[Big Daddy Roth]

I did a little looking around the net. My G60 fw has two marks. TDC and 6* BTDC. The dam marks are so small, they're hard to see. I'll check it out and come back.

[vdubspeed]

DEFINITELY check the marks. g60 may be an upgrade but gasser's don't care much for marking TDC.

[R.O.R-2.0]

I did a aaz swap into my syncro passat. I used the G60 flywheel. Are the TDC marks in the same position??

I have knocking at 'mid-throttle' conditions. I either have to be into the pedal or off of it to achieve no knocking. Cruising is annoying.

I have a giles pump set at .92mm (or at least I think it is). It made similar knocking at .80mm and 0.85mm. I suspect it's my injectors. Time for fresh nozzles?

knocks at mid throttle, then when you go and shift gears at high RPMS right? i had a digifant flywheel on my diesel, and it did the same thing. thought the timing mark was at TDC, but it wasnt, it was at 6*..

so with the crank at TDC, i had everything else set 6* advanced..

[blackdogvan]

I actually got to skip this pain... sort of. With a G60 & a vanagon diesel bellhousing there isn't a tming mark anywhere near the TDC mark so we had to make a piston stopper for a GP hole & do the angular average measurement using a TDC tool & mark accordingly.

Would a AAZ even run at 6-8* advance?

[Big Daddy Roth]

Would a AAZ even run at 6-8* advance?

Yes it can. I`ve been driving like that for a month now.

I rolled it to the correct mark and rolled the pump back a little bit. This fixed my issue. Thanks.

I`ll borrow the tools and time it correctly tomorrow.

[Big Daddy Roth]

Hmmmm

I measured 0.63mm on the dial before i set it to 0.83mm. I'm almost right back to the marks I made on the gear before I moved it back last night. Back to the knocking too.

It ran so smooth, had a good power band, pulled hard, and didn't smoke bad, last night.

Now I'm confused.

Where can I get my own set of timing tools?

[Thezorn]

Hmmmm

I measured 0.63mm on the dial before i set it to 0.83mm. I'm almost right back to the marks I made on the gear before I moved it back last night. Back to the knocking too.

It ran so smooth, had a good power band, pulled hard, and didn't smoke bad, last night.

Now I'm confused.

Where can I get my own set of timing tools?

http://cgi.ebay.ca/VW-Diesel-Injector-Pump-Timing-Tools-Gauge-Injection-/370506845616?pt=Motors_Automotive_Tools&hash=item5643edcdb0
Prothe timing tool set, have heard anything bad about it..
Or just the dial indicator
http://cgi.ebay.ca/VW-Diesel-Injector-Pump-Timing-Gauge-Tool-Injection-/390309146374?pt=Motors_Automotive_Tools&hash=item5ae03cef06

[Big Daddy Roth]

here's a better question.

what size is the 3359 lock pin? my pump uses the small pin, not the larger dowel lock.

[Big Daddy Roth]

here's a better question.

what size is the 3359 lock pin? my pump uses the small pin, not the larger dowel lock.

6mm

[Mark(The Miser)UK]

I think BDR you are 'mixing up' knocking from cam-crank timing error with pump over advance 'knock' error.
The correct position for the pump depends upon the actual dynamic timing of the pump. This is affected by internal pump pressure, timing advance piston pressure response characteristics and injection pressures.
Forget pump locking pins, and spend the money on a  cold  beer. I still haven't found out their true purpose [pins that is ].
Do get a dial gauge as they help you to alter timing methodically, and record where you are when you are 'happy'

Andrew that is an interesting picture, do you know it's history?
If that was indeed a crank to cam timing issue, what is the state of the other 3 corresponding valves?
With a 'normal' head they should have left impressions in the other pistons shouldn't they?
Studying the photo, the valve head and stem section broke off dropped onto piston head, and proceeded to punch the head several times.

Close inspection makes me wonder if this was a piston to valve issue at all? The reason being that the break on the stem is perpendicular to the force, and not with the sloping break, that I think I'd expect.
If you don't mind I would suggest that this may be  a tension failure, from perpetual valve to head   hammering as the valve shuts, and so possibly down to a fault in the valve metallurgy, and so a rare and unlucky event.

Here is a picture of my engine's piston to valve clash. For me it has been going  on for more than 40000 miles, and  is not a timing error but an overzealous hand job head skim. It is worse with the two outer valves,at each end of the head, the exhaust ones, and almost non existent on the inner ones. Note the  gentle kissing of the inlet valve demonstrating that I had nowhere to go with the crank-cam timing. Improved but not cured by moving from a 2 hole to a 3 hole gasket. Since rering last August, economy good, and  four of  last 5 fuel economy checks, over 50mpg [uk]. Still knocking, injectors set to 125bar, and timing 0.7. Pump pressure was at 45psi at 1000rpm...
 

[Big Daddy Roth]

I ran it on some LubroMoly diesel cleaner this am. Big difference in performance, but similiar knock still remains.

I'm getting a set of injectors together to send to Giles for rebuild.

I'm going to check/adjust timing again this afternoon. Set the pump where it wants to run, and go from there.

[R.O.R-2.0]

I ran it on some LubroMoly diesel cleaner this am. Big difference in performance, but similiar knock still remains.

I'm getting a set of injectors together to send to Giles for rebuild.

I'm going to check/adjust timing again this afternoon. Set the pump where it wants to run, and go from there.

have you checked that all the bolts are there for your injection pump bracket?