injection pump timing for aaz adjustable pulley

[paolomarks]

I have an 96 AAZ with the adjustable keyless injection pump pulley. I know how to fine adjust the timing via the dial indicator method and TDC, but how do you initially set the pulley in relation to the shaft and belt. There''s a key way in the shaft and a rectangular notch in the backing adjusting plate on the pulley. Do these line up.  Expert advice needed!  Thanks. Paolo

[burn_your_money]

You are not suppose to take the black hub off of the shaft. It sounds like you did though, correct?

[paolomarks]

Yes I removed the black hub from the shaft.! What now?  Paolo

[burn_your_money]

Well you need a pulley with the cutout for the key. Install the timing gauge like normal. Rotate the pump to 0.95mm advance or whatever you want to set it at. On the back side of the pump there is a bolt that needs to be removed, from there you can lock the driveshaft. Just use a longer bolt. Once you have set and locked the driveshaft in position install the black hub with the timing pin installed. Do not tighten the bolt very much or you will score the driveshaft, break the pump housing or bend the timing pin. Once you have the hub lightly tightened, remove the lock on the driveshaft and remove the timing pin and gauge. Use a holder to hold the hub and then tighten up the driveshaft bolt. Double check the timing and then install the pump.

Since you fine tune the pump once it is on the engine anyways, you should be able to match up the keyhole on the driveshaft and the mark on the hub and put it on and then just eye it up.

[paolomarks]

okay, so i've timed it so that it's .95mm at TDC.  . But how do I know that the pump is shooting fuel to the #1 or the #4 cylinder. ? Isn't it possible that I'm 180 degrees off?  My pulley and injection pump bracket have no place for a timing pin.  Still a bit confused. Paolo

[burn_your_money]

This thread should help explain what I mean
http://www.vwdiesel.net/forum/index.php?topic=16744.0

You need to line the key up with outlet A on the backside of the pump. That will ensure you aren't 180 out.

[paolomarks]

thanks for the replies, still trying to figure her out. "Line the key up to outlet A"  ,  Where is outlet A and how do I make sure it's aligned with the key slot in the shaft. Paolo

[paolomarks]

Okay, as you turn the IP shaft it undergoes resistance every 1/4 turn and then springs foward as the plunger springs decompress. One of these "spring backs"(1/4 turns) leaves the shaft in a position where the keyway slot is pointing straight up, now as you continue rotating in the proper running direction which injector should be firing? As I'm starting from scratch with the pulley /hub position, Seems like if I knew this I could be certain I'm not 180 out.   Thanks, Paolo

[burn_your_money]

Look at the 4 delivery valves. They are stamped ABCD on the steel head.

[nathan_b]

um, there IS a locking key, you can time it just like a 1.6, you just use the pulley instead of the pump. its not that different.

[nathan_b]

it uses a tdi lock in the ip, it also uses an ahu.1z belt.

[burn_your_money]

Nathan, my understanding is that the orientation of the pulley hub is what really sets the injection pump timing when using the pin procedure.  Once the pulley hub has been removed, the normal timing procedure is negated.  The hub needs to be returned to the proper position in order to allow the normal timing procedure again. 

That's correct, and the steps I've roughly outlined above give the procedure for resetting the hub in proper time.

[paolomarks]

Thanks guys for all the help. in reference to " You need to line the key up with outlet A on the backside of the pump. That will ensure you aren't 180 out. "    I still have a question.  A is #1 cylinder, right,  is B #2 cylinder or #3?  ie.is it numerically sequential or  does it follow the firing order (1342)  and how do I line it up exactly with the key slot.?  thanks, Paolo
 
 
 

[burn_your_money]

It will follow the firing order.

You put the key so that as you turn in the direction of rotation it comes up to the letter A, as in it is preparing to inject fuel.