IP swap comments

[DanHoug]

today, well yesterday and today i swapped out my 91 ADA IP for an old low hours 107A that i had resealed. my ADA pump was leaking thru the throttle shaft o-ring, the only o-ring i didn't change out when i had resealed it a couple years ago. i also wanted to get rid of the ADA mechanism for better access to the injectors and GPs.

long story short, it runs great but here's a bunch of comments...

- i had aligned the timing mark on the pump with the mark on the belt cover backing plate, thinking i would tune it by ear when it was running. well it ran like crap when i started it and rocking the pump back and forth didn't seem to help, whilst producing huge clouds of white smoke. i ended up timing the pump with a dial indicator and found i had to have the pump pushed forward of the index mark about 1/4". then it ran fine. how close to the mark are your engines?

- i'm getting a belt whine... not a rubbing sound but a whine. i think it is the timing belt but i also have a new alternator/wp/crank belt (single belt engine!). never had this whine when i've changed belts before. ideas? too tight? i can twist the belt 90 degrees between the cam and IP sprokets.

- put in DieselRX glow plugs as i was down to one working GP. i've been burning thru the Duraterms in less than 6 months so i'm trying a different brand. my nailing at low speed from WVO may be taking them out prematurely.

- speaking of nailing, this IP nails less on WVO than my high mile pump. pretty nice to have the engine access without the ADA blocking the injectors and GPs, too. mainshaft bushing is tight and the pump is clean and shiny!

- this is the first time i've ever played with the smoke screw. dang is that collar ever hard to get off! the amount of smoke that can be produced from these engines is alarming. backed it way out to just a touch of smoke on hard accel.

- this 107A had sat around probably 20 or 30 years but the insides looked great. no diesel in it when i got it but no varnish or rust.

- pump resealing went well with the exception of the throttle shaft spring arrangement. i'd taken pictures but not enough! finally realized my spare engine had the identical pump on it and so i was able to figure out the shaft assembly. my 91 NA is different from my 91 ECO which is different than this 107A.

-dan

[Fatmobile]

When I hear about a whining belt,... I usually think timing belt.

But 90 degrees sounds too loose,.. which can cause the belt to flap between the crank and idler at around 2000 RPM.

[DanHoug]

ack. i mean 45 degrees. it twists up to a 45 degree angle!

-dan

[82vdub]

The timing marks on the IP bracket and pully are for alignment only. Where the mark finally ends up in relation to a dial gauge timing is irrelevant. The marks only insure that you inserted the IP locking pin in the correct hole in the pully, for those pully's that have two timing holes in them. That's it.

[Fatmobile]

Then it could be a little tight.
Just tight enough that it doesn't flap enough to hit the lower timing belt cover at 2000- 2500 RPM, between the crank and idler.
You can watch as you rev and there is a frequency that causes the belt to vibrate the farthest,.. around 2500ish,.. I think.

I think it should be a little looser than 45,... that 45 degree test is hard to judge,.. how hard did you twist when you turned it?? ya know.

Also take note of how much slack there is between the cam and pump. Give it the push-pull.
It should feel a little loose, you want some play.

A little loose on the push-pull.
More than 45 maybe half way to 90,
Doesn't flap against the timing belt cover around 2500 RPM

I don't use a pump locking pin,.. so that mark does help.

[damac]

I have only dealt with a few old pumps thus far. I had one that seemed to do everything the others did at face value, good mileage, cold start advance worked, etc. but I had to swing it wildly towards the head, almost jumped a tooth before finding the right spot. Didn't react like the other pumps where I would start to dial things in beyond the marks. Also these are older pumps that each had their differing issues with leaks and air intrusion.

On the whining I wonder how is your timing belt tracking? After its been run is the belt tracking down the middle and off the lip of the tensioner? When I got my jetta home I didn't know it at the time but the mainshaft bushings were worn so bad the belt was trying to ride off the pulleys and without the help of the tensioner lip it would have been gone. There was half a belt left in there with tons of belt dust. So enough pressure was on the tensioner to slowly slice up the belt. I have had another pump where I could line it up with the bracket so it actually tracked down the middle after a few weeks so I found the magical spot on that one, then sprung a leak

[DanHoug]

my whining noise was a too tight timing belt... took the cover off after about 70 miles and i could see the aluminum imprint of the intermediate shaft pulley. loosened it up to about 67 degrees belt rotation from the 45 i'd previously tightened to and all was quiet.

45 degrees with my thumb and index finger was how i've done 2 previous belts... but whatever, it was too tight this time.

i want to just stare at my engine now.... NO LEAKS! amazing. oil consumption has gone from a quart every 500 miles to about 1/4 quart in 3800 miles.

the 107A is a sweet pump, i love the injector access it provides but i do miss the fast idle control on the cold start lever.

-dan

[Quantum-man]

Remember; if pump is leaning over too much towards ther engine, it is a simple matter to slip the timing belt and rotate the pump and pump sprocket a tooth together

[DanHoug]

that's a good point... i was thinking i would have to move the belt on the crank but it makes total sense to do the correction right at the pump! i need about 1 tooth back.

hey, now that my belt tension is right, the belt rides centered on the pulleys.... it was riding flush with the outside edge.

-dan

[mtran]

NO LEAKS! amazing. oil consumption has gone from a quart every 500 miles to about 1/4 quart in 3800 miles.

You did only IP and get this ?

[DanHoug]

no no no... the IP was just the LAST leak (for now). fixed the crankcase oil leaks with rubber gaskets on the oil pan, valve cover, seals, orings, and opening the crankcase breathers up.

-dan