[Vwdiesel] Timing Help please... Roger? Anybody?

James Hansen jhsg at sk.sympatico.ca
Mon May 5 01:26:28 EDT 2003


> could explain this to me in steps it would be great - I have Jack Ewalds
> directions and they don't make sense to me - how the hell can you zero a
> gauge at 1mm?  that's not zero dammit!

Yeah, Forrest.  As has been pointed out, it's just to keep the dial
indicator point touching the pump internals (plunger).  Don't get weirded
out by the instructions- you need not zero the dial either- just write the
number down really, that's all I do, and all any machinist will do whenever
using a dial indicator.  Turning the dial to zero is really an unnecesary
step as long as you can add and subtract from your starting point.

Briefly:
-Engine at TDC
-Pump turned so the mark on the driver's side of the sprocket is lined up
with the pump casting mark (top) and insert lock pin (only two possible ways
to have this, mark is only on one side of sprocket).
-Cam set so that both lobes on #1 are up, lock plate installed in groove to
hold cam, and camshaft sprocket loose on the camshaft.  Just loose and
barely able to rotate, not flopping around.
-install belt, take up most slack with the adjuster, tighten cam pulley,then
tighten the belt so it can be just moved side to side on the pump pulley.
- remove locking plate and pump pin, turn engine two complete revolutions
(cw), make sure nothing contacts, and the belt cogs are well seated, recheck
belt tension and timing spots(cam plate should still slip in, and pump pin
goes in easy with engine at tdc).
-engine at tdc, install the indicator so plunger is partially depressed,
turn engine backwards until plunger stops (plunger still has to be
touching), write the number down, or turn the dial indicator's outer ring to
get the needle on zero, turn engine back to tdc.  Subtract the two numbers,
or read if set to zero to derive your plunger lift at tdc.
-loosen bolts on pump to turn pump to get your numbers in spec for
application.


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