Club 80-90 Forums

Now then...

Donor car with AAZ is running really badly. I have replace cam belt and re-set up timing, and fiddled with the injector pump (swiveling it) until the car will start without the cold start lever.

To accurately test the timing on the pump I gather you have to stick a dial gauge in the rear of the pump with TDC set etc... (I do have the instructions honest) but I don't know how to mount the dial gauge??

Anyone done this before ~ It is the same procedure on most TD, D engines that we all use (1Y, JX, AAZ etc..) so someone must have checked thier timing ???

TIA

Hutch

look at the end of the pump with the 4 injector lines coming out of it , in the centre between these four lines there is a small bolt head - dial guage screws into here.
1.00mm appears to be the recommended setting.(factory is .8/.9 ish IIRC)

cheers Elvis...

Ordered dial gauge yesterday, am just hoping it has attachements to screw onto....

Did it run bad before cambelt change? Did you replace bottom pulley and bolt at same time.

evening Andy

it ran really badly before I started fiddling! now it just sounds very "toppy". no knocks as far as I can tell from the bottom end and it was a re-con engine 20K ago. some muppet has messed with the heads as there is a spare head and turbo in the boot of the golf!

I didn't even know what a dial gauge was 3 days ago!

any help appreciated

First thing to do is remove crankshaft pulley and make sure the pulley and crank are not worn, common fault on AAZ's and causes bad running before death.

OK will do tomorrow...

how do I know it's worn?
how do I undo the crank bolt? ~ no easy way to lock the crank?

mrhutch wrote:OK will do tomorrow...

how do I know it's worn?
how do I undo the crank bolt? ~ no easy way to lock the crank?

Stick somethinmg throught TDC hole to prevent it turning, don;t use anything that might break.

There is a key bult into the pulley if this moves in the crank you have problems.

if it is okay always use a new crank bolt, they are £1.37 from VW.
Torque to 90Nm + 90°.

nicely... Will order that from firendly VW garage here tomorrow.

The AAZ is still in the golf, and someone has buggered up the allen key bolts on the outer pulley on the crank so I can't get the aux. pulley off with the engine in situ.. so I can't see if there is a locking hole or not in the crank pulley (am I making sense??)

so, I could

• weld a bolt to the allen-headed bolts on the aux pulley purely for the purposes of undoing it so I can get the AAZ running well before transplant
  
  sod it and get the AAZ running as well as I can and pull it over the weekend, at which point I can get medieval on the bolts holding the aux. pulley with the engine safely removed from car
  

what would you do?

mrhutch wrote:nicely... Will order that from firendly VW garage here tomorrow.

The AAZ is still in the golf, and someone has buggered up the allen key bolts on the outer pulley on the crank so I can't get the aux. pulley off with the engine in situ.. so I can't see if there is a locking hole or not in the crank pulley (am I making sense??)

so, I could

• weld a bolt to the allen-headed bolts on the aux pulley purely for the purposes of undoing it so I can get the AAZ running well before transplant
  
  sod it and get the AAZ running as well as I can and pull it over the weekend, at which point I can get medieval on the bolts holding the aux. pulley with the engine safely removed from car
  

what would you do?

knock an 8mm spline socket in the bolts, that should do it, if not 12 point socket over outside if bolts.

hahaha thats what I like to see, some good old northern engineering!

previous owner looks like they have tried to weld a bolt to the allens as they have splatter all over them. I may just end up tacking a bar to each one.. just seems like a bit of a hassle when the job is easier when the AAZ is hanging on an engine hoist and I can just grind off the allen heads and remove the outer pulley

Trouble is "little hutch" on my right shoulder says fettle the engine before you lift it from the golf...

mrhutch wrote:hahaha thats what I like to see, some good old northern engineering!

previous owner looks like they have tried to weld a bolt to the allens as they have splatter all over them. I may just end up tacking a bar to each one.. just seems like a bit of a hassle when the job is easier when the AAZ is hanging on an engine hoist and I can just grind off the allen heads and remove the outer pulley

Trouble is "little hutch" on my right shoulder says fettle the engine before you lift it from the golf...

If you undo the centre bolt the whole lot will come off an d you will have better access.

brilliant... Thanks Andy

I didn't think of that.

Right , took the pulley off today as we spent yesterday removing the engine from donor golf and dropping the JX from sick van.

Pulley :
[img769]http://www.mrhutch.net/DSCF6256_l.JPG[/img]

Crank:
[img769]http://www.mrhutch.net/DSCF6262_l.JPG[/img]

ARRRRRRRRGGGHHHH

is the crank knackered??

Andy, Sir Baxter.. opinions?

(Also posted on the Yard.. for max exposure, sorry if this pi$$es anyone off)

TIA

Hutch