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Engine Mechanical

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Mechanical VE IP Timing (CS,1Y,JX,AAZ,mTDI)

Both of the below tools can be used together. Once you find the fine spot you like with the timing gun, use the dial-gauge to get a value.

Once you have a value that should work for similar setups, or damn close.

They do work on two different means, but complement each other well

Dial Indicator Gauge

This is a cheap effective way to do timing if you are given a known value. Such engines as the 1.6na (CS), 1.6td (JX), 1.9na (1Y), and 1.9td (AAZ). These Injection Pumps came from VW and the Bentley as many other VW resources can give a value to target for the best timing.

Ryan Turner from VWDiesel.net created this video which is good reference of what to do.

What if you're running a non-standard/custom/performance/mTDI Injection Pump and nozzles?

Diesel Pulse Adaptor

If you're using a non standard VW Injection Pump setup as non-standard nozzels, or even if you are, you can use an Advance Timing Light with a pulse adaptor to time your engine similar to a gasoline engine. This method is also good, if you have similar components. In theory, if two people had a mTDI setup of similar configuration, one used the timing gun and then obtained the dial-indicator for a value. That general dial gauge value should be a cunt hair within spec on an identical setup (same Bosch IP P/N, nozzles, pistons/engine, etc.

The main difference between a dial-indicator / timing-gun besides the static vs dynamic timin values is; the timing-gun accounts for the wear/deviation of parts getting out of spec. A dial-indicator static setting assumes a tip-top engine. Then you got the within-specs.

Snap-On makes the MT257B currently, but previous MT257A works as good. The A version was made in USA and the B version made in South Korea.

Another good option is the DTI-3300s made in USA in Illinois.

How To

Clamp the inducer for the injector line on either injector 1 or injector 4.

The best place use the timing light is off the flywheel TDC mark. I would use yellow paint on the grove and mark your pointer easy.

To use the timing light, when you shine it down at the flywheel mark; the mark and the strobe appear as one--that's the degree you're engine is currently at.

From my research of those who have used this method it appears 12deg +-1/2 a degree seems to be the sweet spot for most VE TDI based IPs.

Sorry no photos or videos, the strobe effect doesn't record well and with my epilepsy I'm trying to avoid looking at it too long.

Reference

VWDiesel.net Discussion/flam war

Peachparts.com - Inquiry from Libby

OilBurners.net - Decent over-view of the various adaptors available. This covers more the Ford 6.9 / 7.3 IDI, but the Diesel Pulse Adaptor information is valid.

Exhaust Related

Oil Pan Muffler Mount

P/N 033251393 alt crossreference

1.6na (CS)

1.9 (1Y)

1.9td (AAZ)

CCV Mod

The AAZ has poor CCV at 50deg, upgrading to a TDI CCv setup helps.

TheSamba Reference

Clutched Alt Pulley

Gates 37010P

028903119AA

You'll need a tool/socket for this ebay search Bosch 8088 tool

1.9tdi (1z/AHU)

Headgasket

Sometimes you need to replace it with a new or unknown head.

If so this article on measuring piston protrusion

You'll need a tool/socket for this ebay search Bosch 8088 tool

1.9tdi (1z/AHU/ALH)

Everything under this category is the same/shared between the three engines such as accessory parts.

Clutched Alt Pulley

Gates 37010P

028903119AA

You'll need a tool/socket for this ebay search Bosch 8088 tool

Injector Nozzel Anatomy

Reference

The anatomy of the injector is pretty much the same between the three engines.

[https://www.myturbodiesel.com/d2/1000q/multi/nozzle-install-TDI.htm How to install replacement 1.9 TDI nozzles