Timing the IP with an indicator

[libbydiesel]

Gizmo, from looking at your various pics it appears that you have a 1.6TD pump body.  I'm sure if you had Giles go through it he did what was necessary internally to make it work ideally for an AAZ, but the sprocket must match the pump body.  The snout of the AAZ pump has a different offset.  Sooo, if you have the short 1.6 snout you need to use a 1.6 sprocket.  If you have a long AAZ snout you must use the AAZ sprocket.  With the matching sprocket, either pump can be installed on either engine and the correct sprocket offset will be maintained.

The pump sprocket is keyed and so cannot lose it's orientation with the shaft.  That said, even if it does, the engine will not be damaged.  Disaster only results when the cam and crank get out of time with each other. 

[Gizmoman]

Your right on the pump - its a 1.6 nose.

As usual, I can't keep my head screwed on right with this thing.
Doing this on weekends after a high pressure week at work is just too much sometimes.

I already ordered the sprocket from Hans - 28 bucks with shipping.

I guess I'll get another one for a 1.6, balance the one I have by milling off some iron, or just ignore the balance issue altogether

[8v-of-fury]

Oh boy, lol.

I am sorry you have a high pressure/ high stress work week buddy. Because there is nothing worse than trying to get stuff done when your brain is mush and you cannot think straight.

One sentence of advice however? Do not over complicate. lol

If what you had was a proper 1.6 pulley then there should be no issue what so ever to undoing the pump mounting bolts. Are you sure you had your two way pulley in the right spot? The pumps shaft key way should be pointing up an to the left when looking at the snout, or roughly in the 10-11 o'clock position. When the pump is at TDC, it should look exactly like how this pulley is positioned. Which as you can see will put the two bolts in reach, one at the bottom and the other across from the lock hole.



I am pretty sure you have the pump at a different spot than TDC if you cannot get a socket on the nuts through the pulley. Please take the nut off the pulley and show us in a picture what it looks like at TDC.

I will try my best to help you with whatever you need, feel free to PM me with any questions you have about whatever you need to know lol.

[TylerDurden]

Looks like Gizmo has an early sprocket with the stupid hole, same size as the lock pin hole.

The 18 buck jobbie is the right one. I have four in cars, two on the shelf, all for 1.6 litre IP.

[Gizmoman]

Trust me, I'm not whining, just tough to change gears sometimes - should have just stepped away from the project.

I'll take it all back apart in the morning and get some photos. I installed the pulley after I had machined it and buttoned it all up.
The arrow on the pulley edge is pretty much dead on with the center-mark on the IP. Don't recall where the key was exactly except that it was to the left. I'm pretty sure it is located exactly as shown in the photo of the Hans sprocket.

The pulley I already ordered is for a 1.9 pump (based on the part number). I thought the noses were the same but according to libby, they aren't, so I ordered the wrong sprocket. My IP is a 1.6 - Giles tweaked it to perform for my application goals and said it was essentially a 1.9 now (internally).

I think I'll do some machining on the one I have to get it back to balance. I don't see any point in buying another 1.6 pulley as I like the fact that I can reach both nuts when it's all lined up. Had I come to the simple realization that getting to those two nuts while it was at TDC wasn't required, I wouldn't be writing this, but I was so focused on the task, I was blind.

I will take some photos though and appreciate your offer very much.

Cheers,
Gizmo

[745 turbogreasel]

Can you make those  nuts one part with the bracket like the 2.5?

[CRSMP5]

tin on a tdi (trying to rember what one though??)  has captured nut... id try to fab that nut into it... has a cage to keep it in place...

[Gizmoman]

tin on a tdi (trying to rember what one though??)  has captured nut... id try to fab that nut into it... has a cage to keep it in place...

There is one captive nut on the tin as you can see in the photo (upper right). This is the only bolt I needed to tighten and I could have easily with a wrench. Then just rotate the sprocket till I got the other two.


Here's another pic with the alignment pin in place. The arrow on the sprocket edge lines up with the mark on the pump housing.



Here's another angle. If you look real close at the edge of the sprocket, you can make out the mark. . .


I think I have it timed pretty close.

The 1.2 ounces removed could produce 22 ft/lbs of force on the IP bearing at 2500 RPM. I think I need to do some more milling or get a new 1.6 sprocket. Does anyone have a part number - mine has a few missing

[8v-of-fury]

That pulley lined up perfectly before and needed absolutely NO material removed in order to fit a 13mm socket on those nuts.

Done it about 75,000 times personally haha.

[Gizmoman]

As requested - here's a shot showing the keyway position when "timed".

[Gizmoman]

That pulley lined up perfectly before and needed absolutely NO material removed in order to fit a 13mm socket on those nuts.

Done it about 75,000 times personally haha.

I probably could have fit the socket on one of the nuts (lower right) had I turned the pump a few degrees. The other nut (on a stud) was lined up with the "stupid" small hole opposite the pin hole. may my 1/4" drive 10 mm would have fit that one

[libbydiesel]

For balance, you could make the three holes that are in front of the three pump fasteners match and then make the other three holes match.  Make a bushing for your alignment pin.  Mark the correct hole because you'd then have two 'stupid' holes.

[Gizmoman]

For balance, you could make the three holes that are in front of the three pump fasteners match and then make the other three holes match.  Make a bushing for your alignment pin.  Mark the correct hole because you'd then have two 'stupid' holes.

Good ideal libby. I just did this. . .



The diameter of the c'bore is larger than the opposing "access hole", I'll bet its pretty close to balanced now.

[libbydiesel]

Perfect.

[745 turbogreasel]

Unless the pump happens to be mistimed inside.