[Vwdiesel] Timing Belt Change: I know I goofed--how much?

[LBaird119 at aol.com]

In a message dated 4/5/2006 7:52:08 AM Pacific Standard Time, 
jwchou at yahoo.com writes:

> At this point, I think I
> have to abandon all my marks and start over again with the real TDC 0 mark. 
> The
> question is how do I line up the camshaft to TDC without the tool 2065? Or I
> must have this special tool to do the job right? Secondly, when I line up 
> the
> hole on the IP sprocket to the bracket hole to allow the insertion of 5/8"
> round bar(tool 2064) the small round dot on the IP sprocket does not line up
> with the mark on the bracket at the top, is that ok?
> Thirdly, is it possible to do the IP timing without the dial gage? 
> 

  Jeremy,
  You can simply "eyeball" the cam in for TDC.  I have the plate and 
only put it in last just to verify what I've already eyeballed in and I don't 

think I ever end up adjusting it.  :-)
TDC on the crank, as you probably now know, is the 'o' mark between 
those two bosses you found.
  The pump gear should come out awfully close to the mark on the mount
when you pin align it to the pump mount.  There are two holes that will line 
up. They should set parallel to the ground and the hole only allows a 
couple of mm of your pin to sit in it. (the hole in the mount).  If you use 
the wrong hole (180 off) then the timing mark on the gear will be on the 
bottom instead of the top.
  Simplest way to assemble it all is to pop the cam gear loose, line it all 
up, slip the belt on putting the cam gear in it last.  Then put the gear in 
place, slide it on the cam and finger tighten the bolt to almost snug.  The 
pump will most likely end up one tooth off due to the internal spring action.
Rotate it about a half tooth against the direction it wants to go when 
putting the belt on. 
  Now tension the belt, recheck and then tighten the cam bolt lightly 
then with a whack from your palm.  That'll tighten it quickly and not 
change the timing.  Recheck all marks.  
  If the timing was correct to start with then it'll be correct now, 
providing 
you got the belt tension correct (NOT TOO TIGHT and DO NOT TWIST the 
belt!!!)  You about need a dial to set the pump properly unless you want 
to try trial and error.  
  By ear the engine should start well with the cold start knob out and falter 

a bit in the first few seconds with it in.  You should distinctly hear a 
difference.  Warm you should just barely be able to hear a difference in 
the engine with it out and in.
     Loren