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

[Mary Beth and Chris Geiser]

The only thing I would clarify is to make sure you have the big (approx
1 to 1 1/2 inch) cover plug out to see the mark for TDC on the flywheel.
I've read where a few people (myself included) tried to find a TDC mark
through the little plastic plug hole in the middle of the big plug.  You
won't see the marks unless the big plug is out.

Chris

-----Original Message-----
From: vwdiesel-admin at vwfans.com [mailto:vwdiesel-admin at vwfans.com] On
Behalf Of James Hansen
Sent: Monday, May 05, 2003 1:26 AM
To: Vwdiesel
Subject: RE: [Vwdiesel] Timing Help please... Roger? Anybody?


> 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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