AAZ Injection pump timing issue

[TylerDurden]

Are you absolutely 100% the mark you have as TDC is actually TDC?? This is a fresh built motor, did you use a Gasser flywheel? Are you by chance using the 6* mark for the gassers?

Can the crank be 6^o off without valve clash?

[vwzzuk]

For the 1.9 Pulley, it only has one locking pin location. So, I timed it to the stock location and marked the tooth opposite to it and the timing belt. I used that tooth mark as my 180 degree out mark. It would not run 180 degrees out.

With the 1.6 pump, it has two holes but I only used the stock TDC locking pin location for testing.

Diesel flywheel timing mark is bang on. I also verified it with testing the location of the piston through the combustion chamber with the injector & glow plug removed.

I don't see how the crank and cam can be off TDC mark or 6 degrees when they are tied together by a new timing belt when timed correctly.

I'm using a stock 1.6 Injection pump bracket (the stamped steel version) compared to the 1.9 cast bracket (that only fits on the 1.9 block).

Going to dig in into it again today.

[wolf_walker]

Wait, my 1.6 pump pulleys only have one timing lock pin hole. It has a mark to line up too. I'm looking at one hanging on the wall now.

Sent from my SCH-I535 using Tapatalk 2

[8v-of-fury]

Wait, my 1.6 pump pulleys only have one timing lock pin hole. It has a mark to line up too. I'm looking at one hanging on the wall now.

Sent from my SCH-I535 using Tapatalk 2

Two different kinds. Early ones I believe that had the two holes.

[vwzzuk]

Yes, I have both 1.6 version pulleys.

I put a new timing belt on to see if there was a difference between the two belts. Nada. Both have 135 teeth and run the same though one is easier to get on the cogs.

I'm going to move the belt a tooth, retime it and see if it makes it run right with a better amount of adjustable advance.

I'm perplexed. I've done a number of rebuilds and I have never run into this before with any of them. Totally weird.

[8v-of-fury]

I don't see how the crank and cam can be off TDC mark or 6 degrees when they are tied together by a new timing belt when timed correctly.

But are you using the correct TDC mark on the flywheel is what I meant.. If you could snap a picture down through the inspection hole for where you see the flywheel at TDC we could rule that right out.

[vwzzuk]

Sorry for the confusion. Yes, the correct TDC mark is being used on the flywheel. Same position for the cam and IP using the correct German timing tools.

If I show you a picture, you would think I'm from a different planet, and have it all wrong. LOL! So, I guess I must say that you caught me. The engine is in a different vehicle, using a different transmission and machined flywheel with only one mark at TDC. Now before you say, "ah, there's your problem", let me humbly suggest that I've done over 30 of these and all done the exact same way without issues and all running fine.

[8v-of-fury]

Well until this moment, I had no knowledge of your experience levels.

So. If you have done 30+ of these conversions, maybe you should tell us what the problem is? LOL

[vwzzuk]

No, no, no, no. Iron sharpens iron. That's why I need YOU!
LOL!

[wolf_walker]

Wait, my 1.6 pump pulleys only have one timing lock pin hole. It has a mark to line up too. I'm looking at one hanging on the wall now.

Sent from my SCH-I535 using Tapatalk 2

Two different kinds. Early ones I believe that had the two holes.

Ahh, gotcha.  I can never remember stuff like that, just saw one hanging on the wall and wondered.

[vwzzuk]

Still trying to figure this out.

Two questions:

1) What is the total timing movement (from Advance to Retard) measure on your injection pump?
2) Is the range of timing travel (from advanced to Retard on the injection pump) the same on all 1.6 & 1.9 injection pumps?