No start after TB????We Got Fire!!!!

[kneale at knitknacks.com]

I tried to start the whole process with the flywheel mark.  Very difficuly
to see a rusty groove on a rusty flywheel in a tiny hole through a bunch of
hoses and wires from the distance away the fender is with 70-year-old eyes
looking through trifocal glasses.  That's why I relied on the cam mark and
the TDC "gauge" I made years ago from a piece of Maple dowel with marks on
it.  

Original Message:
-----------------
From: Tihol Tiholov t.tiholov at gmail.com
Date: Fri, 23 Oct 2009 10:22:49 -0700
To: quattro at audifans.com
Subject: RE: No start after TB????We Got Fire!!!!


>
>
> Message: 6
> Date: Fri, 23 Oct 2009 09:28:24 -0400
> From: Kneale Brownson <kneale at knitknacks.com>
> Subject: Re: No start after TB????We Got Fire!!!!
> To: Mike Sylvester <mike at urq20v.com>
> Cc: quattro at audifans.com, 200q20V mailing list <200q20v at audifans.com>
> Message-ID: <4AE1AF78.80303 at knitknacks.com>
> Content-Type: text/plain; charset=UTF-8; format=flowed
>
> I'm trying to figure out how I got the timing off when I didn't move the
> crank or the cam during the initial timing belt change.  What I recall
> is that there was almost no tightening of the crank pulley.   I set up
> my usual 24-inch breakerbar and piece of 3-foot pipe to loosen the bolt,
> kind of dreading the effort because it's  sort of left-handed and that's
> the side that hurts,  and when I pushed on the pipe with my right
> hand,  there was almost no resistance.  I could have used a ratchet and
> socket.   What I think now is they put the pulley on without engaging
> the  key in the  crankshaft keyway,  so when I lined up the pulley with
> the keyway and installed it,  the timing relationship changed.
>
> You cannot rotate the crank 180 degrees by itself.  I had to turn the
> crank however far it'll go, reinstall the belt, turn some more to clear
> the interference, uninstall the belt, turn the crank some more,
> reinstall, etc., until I could get both the dot on the camshaft pulley
> aligned with its mark and the mark on the flywheel in the right spot.


Maybe that's why the shop manuals say to align both crank and cam marks at
TDC before taking the T-belt off and check them during installation.  Then
rotate engine by hand and check them again before starting the engine.   I
see how that might have been hard with your injury.
Best,
Tihol
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