[Vwdiesel] Injection timing of Old Volks. # 6 - ( the saga goes on and --)

[H .Hagar]

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" Injection timing of Old Volks # 1"     can be found at 31 July 2003.    I=
t is necessary to read it all.      A condensed version may follow later.  =
     After all the things you have done so far   like adjusting valves , ch=
ecking compression and trying to get to that ridiculous dial indicator tole=
rance.   0.0007874 inch. That is definitely a "C" hair.    No amount of per=
fection will do the job if Dynamic timing is not working properly.  So we a=
re doing two things , to get power with no smoke.   1. getting timing to wo=
rk.  2. finding optimal setting for pump by sound and feel and power --- St=
andard settings do not work for OLD pumps and injectors and valves.. This p=
rocedure is very inexpensive, but it does take time, since we drive between=
 adjustments.      Lets refresh why timing quits on these VE pumps.   crapp=
y fuel crappy fuel and more crappy fuel. With proper fuel they would go on =
for a long long time. Do a  google search Bosch VE pumps  --- incredible ho=
w many pumps failed at 60 000 Km's.  And VW saying no to warranty claims ev=
en under smoke laws.Here is what goes wrong The vanepump vanes wear and tim=
ing piston bore (housing body of pump) wears letting thin fuel leak by . Th=
at together ends up as no ability to move injection point (advancing) so en=
gine can accept more fuel without smoking. If at the same time there is a l=
eaking seal or o ring , situation will be way worse.    Make a special 13 m=
m wrench as follows.Take a standard 1/2 " or  13mm  1/4 inch drive socket.G=
et a toy one soft steel  and drill hole lengthwise so socket will slip on f=
uelling screw. then silver solder a handle to outside for turning . Use  im=
agineering.This to be able to use wrench and screwdriver at the same time. =
Mark Shepherd you are a fellow hillbilly fixer  ---  how's am I doing so fa=
r ???.
Timing piston is heavily anodized aluminium  Diameter  55 thou short of an =
inch. Length 2 " 150 thou.  Returnspring  Coil
1=2E4 "    wire  100 thou   7 turns colour green.Internal pump pressure at =
idle  about 30 psi   at speed more than 80 psi.
The first day that you drive that car , and it climbs that hill in high gea=
r without smoking (like mine did) send me an "attaboy"     .           I am=
 ashamed that it took me so long to figure out.           Hagar.          H=
ave fun.
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