New Distributor Gear installation instructions

[Lino M. Valadas]

Thanks Bernie.

I didn't think so. However I did not get a pin with my gear, so do you know
what the dimension of the pin are?  So that I can procure one before
tackling the job.

TIA

Lino



----- Original Message ----- 
From: "Bernie Benz" <b.benz at charter.net>
To: "Lino M. Valadas" <l.valadas at rogers.com>
Sent: Sunday, November 20, 2005 11:43 PM
Subject: Re: New Distributor Gear installation instructions


> I supplied a standard inch series roll pin with my gears, the old pin will
> be junk.  Shims are probably not necessary.
>
> Bernie
>
> > From: "Lino M. Valadas" <l.valadas at rogers.com>
> > Reply-To: "Lino M. Valadas" <l.valadas at rogers.com>
> > Date: Sun, 20 Nov 2005 23:36:05 -0500
> > To: "Bernie Benz" <b.benz at charter.net>
> > Subject: Re: New Distributor Gear installation instructions
> >
> > Bernie,
> >
> > I did not receive a pin and shim with my gear.  According to your notes
the
> > pin seems to get destroyed during removal.  Is the pin salvable for
reuse or
> > should I look for a new one?
> >
> > Thanks
> >
> > Lino
> >
> >
> > ----- Original Message -----
> > From: "Bernie Benz" <b.benz at charter.net>
> > To: "Lino M. Valadas" <l.valadas at rogers.com>
> > Sent: Wednesday, October 26, 2005 11:45 PM
> > Subject: FW: New Distributor Gear installation instructions
> >
> >
> >>
> >>
> >> ----------
> >>> From: Bernie Benz <b.benz at charter.net>
> >>> Date: Wed, 12 Nov 2003 12:00:13 -0700
> >>> To: Lou Martin <lou.martin at afscn.com>
> >>> Subject: New Distributor Gear installation instructions
> >>>
> >>>
> >>>
> >>>
> >>> I.  Preliminaries: Bentley ref pgs:  3B: 28.47, early 7A: 28.250
> >>> (The Audi distributor alignment tool is not necessary.)
> >>>
> >>> 1.  Rotate the engine to #1 TDC.  Rotor pointing to #1 plug terminal
and
> >>> 0-degree flywheel mark at pointer edge.  Get this right!
> >>> 2.  With dist cap and Hall sensor connector removed from the dist and
> > other
> >>> junk out of the way as much as possible, note the angular position
> > relative to
> >>> horizontal (3B), or vertical (7A) of the Hall sensor connector and the
> > rotor
> >>> (these will be opposite each other) for later return to original
> > oriention
> >>> purposes.
> >>> 3.  Remove the anti-tamper cover, if any, on the dist hold down clamp
> > nut,
> >>> located on the stud in the head under the dist location hole, remove
nut
> > and
> >>> clamp.  I removed the anti-tamper device by hacksawing a slot across
the
> > top
> >>> of it and then unscrewing it with a flat blade screwdriver.  They
> > usually
> >>> aren't on very tight.
> >>> 4.  Pull dist from its locating hole, noting that the rotor turns
> > clockwise
> >>> about 1/4 inch as the dist gear is withdrawn from its mating cam gear.
> > Upon
> >>> reassembly it must go back in with this same final removal orientation
> > to end
> >>> up in the same original position.
> >>>
> >>>
> >>> II. Plastic Gear Removal:
> >>>
> >>> 1.  Don't try to drive out the retaining pin yet!  Remove the gear
> > plastic
> >>> from its steel hub by hacksawing 2 or more diagonal cuts thru the
> > plastic to
> >>> the hub, pry or chew off the pieces.
> >>> 2.  Note that both ends of the groove pin are swaged larger than the
pin
> >>> center dia.  Saw off the smaller pin end and file it flush with the
gear
> > hub.
> >>> 3.  Support the gear hub and shaft in a suitable V block or vice jaws
> > and
> >>> drive out the pin using a 5/32" dia pin punch or an old nail on the
> > filed end.
> >>> 4.  Remove the gear hub and retain the shim washer pack for
reassembly.
> >>> 5.  Remove the shaft, not loosing the fiber thrust washer at the top
> > end, and
> >>> clean the dist body and Hall rotor.  If there is any oil in the
> > distributor,
> >>> service the crankcase breather system.  (This distributor does not use
a
> > shaft
> >>> seal component, just a reverse spiral groove on the shaft in the top
> > portion
> >>> of the upper bushing.)
> >>>
> >>>
> >>> III.  New Bronze Gear Installation:
> >>>
> >>> 1.  Install the original shim pack on the shaft, followed by the new
> > gear.
> >>> align the smaller gear pin hole with the shaft pin hole.  (Do not use
> > the
> >>> larger pin hole, it is a vendor goof.)  Support the gear hub on the
far
> > side
> >>> (not on the gear teeth) and tap the roll pin part way into the shaft.
> > Check
> >>> the dist shaft axial clearance.  It must not be tight, but should have
2
> > to 5
> >>> thou end play, a "just perceptable free movement" feel without
binding.
> > If
> >>> not so, remove the gear and adjust the shim pack, + or -, as required.
> > An
> >>> additional .003" thick shim is provided with the gear and roll pin to
> >>> faciliate this adjustment.  Add or subtract different thickness shims
> > until
> >>> the end play is the closest to the "feel" spec.  Unlikely, but if more
> > or
> >>> different thickness shims are necessary, they can be cut from paper
and
> > added
> >>> into the center of the shim pack.
> >>> 2.  Drive the roll pin thru the assembly and center it in the gear.
> > Recheck
> >>> the axial clearance "feel".
> >>>
> >>>
> >>> IV.  Distributor Installation:  without VAG alignment tools.
> >>>
> >>> 1.  Remove the black plastic shield which may have been covering and
> >>> seperating the Hall area of the dist. body from the rotor.  Not all
20V
> > dist
> >>> have this shield, which may be replaced just prior to reinstalling the
> > dist
> >>> cap.
> >>> 2.  Notice that there is a line embossed on the top surface of the
Hall
> > rotor
> >>> immediately under the hot end of the dist rotor, and a mating line
> > notched
> >>> into the top edge of the distributor housing opposite the Hall
connector
> > and
> >>> just above the Hall sensor unit.  When finally in place and locked
down
> > these
> >>> two lines must line up with each other with the engine at TDC.
> >>> 3.  With the dist and rotor lined up about as it was as you removed it
> > (you
> >>> forgot where that was, didn't you?) insert the dist, moving the rotor
as
> >>> necessary to get the gears to mesh.  Once all the way seated in place,
> > while
> >>> applying a slight counterclockwise finger bias to the rotor (thus
> > eliminating
> >>> gear mesh clearance), adjust/rotate the dist body to exactly line up
the
> > two
> >>> marks, and lock it down (lightly, you may have to move it again) with
> > the
> >>> clamp and nut.  If you are not happy with the resultant orientation
> > angle of
> >>> the Hall connector, pull the dist just enough to free the gears and
> > rotate the
> >>> rotor one gear tooth in the same direction that you would like to move
> > the
> >>> Hall connector when the two marks are again lined up.  The distributor
> > will
> >>> work in any oriention, as long as the two lines are lined up at TDC,
the
> >>> actual oriention just facilitates the electrical connections to the
Hall
> > and
> >>> dist cap.
> >>> 4.  All 200 owners who elected to short cut and not remove the intake
> > manifold
> >>> per Bentley, must now curse loudly at the Audi gods for the
> > inaccessability of
> >>> the whole dist system and the dist cap hold down clamps in particular.
> > 7A
> >>> owners need not comply.
> >>> 5.  "Reinstall all components in reverse order of removal".  More of
> > Bentley's
> >>> sage advice.  If the engine won't start, recheck your TDC position for
> >>> accuracy and then the distributor marks alignment for its accuracy.
> > They must
> >>> be right on.  Do not attempt to move the dist with the engine running
as
> > you
> >>> did with those old point type dist, as this dist does not determine
> > engine
> >>> ignition timing.  Thank you for flying united.
> >>>
> >>> E-mail if you have any serious problems with your installation or with
> > these
> >>> instructions.
> >>>
> >>> Bernie