[alfa] Finding top dead center

["John S." <roadtrip999@xxxxxxxxxxx>]

Steve - First of all, the injection pump is NOT timed at TDC on the #1 
cylinder. To time the injection pump correctly:

Remove the spark plugs and SPICA pully cover.

1. Set the engine at TDC at start of power stroke, (both valves closed and 
"P" mark on crankshaft pulley) on the #4 (NUMBER FOUR) cylinder.
2. Then, rotate the engine COUNTERCLOCKWISE (as you are standing at the nose 
of the car looking towards the rear) to the "I" mark on the crankshaft 
pulley. It'll be about 70 deg of rotation, I think.
3. Look for the index marks on the injection pump pulley and the front of 
the injection pump body.

My Questions:

   Where the other TDC mark is (the one not on the injection pump), and can 
it be seen without removing the radiator.

   Is there a better way to rotate the engine?

Remove the spark plugs and you should be able to rotate it by hand fairly 
easily. Removing the hood makes working on the engine easier.

   Could the mark on the gear of the injection pump be worn off?

No. It's pretty deeply scribed in to the metal.

   Whats the best way to remove the metal gas lines?  Either from the head 
side or pump side?

Pump side. Helps to have a "Shortie" wrench to secure the fuel towers while 
you loosen the fuel pipe nuts. Soak the nuts with some PB Blaster or some 
other penetrating oil the night before to help break any corrosion. Remove 
the fuel pipe stays on the bracket. Don't bend or deform the fuel pipes. 
Loosen the outside pipes (#1 and #4) first, then #2 & #3.  If the pipes look 
corroded, it may be best to remove them completely, and clean them. These 
pipes are no longer available as spares, so take care of them.

   Finally any tips on removing the pump a firsttimer might not think of.

Instead of removing the pump base from the engine block, remove the 6 nuts 
holding the pump section onto the pump base. Once the pump is off the base, 
you can easily get to the 4 nuts that hold the base to the engine block.

If you like some pictures of what the index marks look like or where the 
pump comes off the base, send me an email address and I'll send them to you. 
 roadtrip999 NOSPAM @domain.elided
Of course, delete the NOSPAM and space before and after.

John

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