[Vwdiesel] re: *help* - '93 EuroVan diesel jumped time

[mikitka]

Sorry to hear all the problems. But as you might know I was just there
myself. To get my set up timed I pulled the cam off all the lifters so the
valves would all be closed and then I rotated the crank to TDC. You should
be able to see if a valve is hanging with the cam out. I'm not familiar with
that engine but isn't it close in nature? I know my crank bolt is on good
and tight, that half turn after the initial 61lbft torque really got it
tight that's for sure.
Nick

-----Original Message-----
From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com] On
Behalf Of rOLf peCHUkas
Sent: Wednesday, June 15, 2005 9:33 PM
To: vwdiesel at vwfans.com; ev_update at yahoogroups.com
Subject: [Vwdiesel] re: *help* - '93 EuroVan diesel jumped time

well, I just called it a night
dark and rainy and here's the update:

removed the crank pulley/timing belt sprocket/crank-cam T-belt

key is gone, little metal dust where it used to be

key slot on the crank looks OK, T-belt sprocket key slot is trashed 
(shows where the good metal is)

mating surfaces similarly scratched up, on both the crank and the 
sprocket
crank seal partially shredded

made up an emergency key out of the end of an old toothbrush, hot-melt 
glued it into the key slot, reinstalled the crank pulley

crank and cam/pump were @ 20-30° out of time (!!)
(cam is still timed to the pump due to dual T-belt configuration)

started inching crank and cam/pump back toward TDC

curious miscellaneous sounds coming from up in the head

got both back in the vicinity of TDC
BUT
crank will not go all the way to TDC
I can get w/ in 5° of it going either direction
at one cam position I can go all the way around @ 350°
but something is preventing crank from going all the way to TDC
I tried a bunch of different cam positions, no go

so, need to pull the head
must be a valve permanently down, a broken spring, something keeping 
something stuck down in the way on #1 cylinder

will keep y'all posted

(any hints, suggestions, wiseacre remarks, insults welcome)(yes, it was 
me that torqued that crank bolt down - maybe I shouldn't have put that 
fine layer of assembly grease on all the mating surfaces)(kidding)
-- 
Rolf
Cambridge, MA
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