[Vwdiesel] changing the timing belt -progress report

[MLightner]

Greetings listees, and Happy New Year;

Thanks to everyone's suggestions and info on setting up the timing on  
my 85 1.6TD, the second attempt to do so went successfully, with little 
trouble. 

It turns out that when I was originally attempting to set up the crank 
at TDC, I'd assumed that the 0 degree lug should be centered in the 
inspection port because I wasn't looking  in there from enough of an 
angle to see the arrow and line up the mark with it.  Once I figured 
that out, it turned out that the cam and crank could be brought  into 
perfect agreement without moving the cam sprocket on the shaft. 

So, having loosened the cam-sprocket bolt but not yet managed to get it 
loose from the shaft, I was able to leave things alone there for now, 
but did get to make a new special tool so as to have a way to hold the 
cam in place while torquing the bolt back down - (it's basically a big 
pin-wrench, sorry I don't have a decent  camera right now to post pics 
of it with...)

It took awhile to get the pump re-primed, after it sitting a couple 
weeks. I finally used an electric fuel pump patched intothe supply line 
just before the filter - I suspect I need to try and chase down a leak 
somewhere in the fuel lines, as this thing has lost prime before just 
sitting for a day when parked not pointing down hill. 

Anyway, I also replaced the waterpump and t-stat, and one warm-up 
cool-down cycle seemed to be enough to get it to take in the same amount 
of coolant as I drained out of it. It feels good to be familiar with how 
the A/C unit and the bracketry and adjustments are done on this thing 
now,  though I certainly don't consider the setup technical wizardry,
(whats up with this mid-eighties so-called engineering, anyway?).

After a thorough warm-up I checked the valve clearances and found them 
all within tolerance  (.010" for the intakes and .015 to .018" on the 
exhaust valves), I must say, much to my surprise.  The time I spent 
messing about with the IS
was also most beneficial, as it turned out that one of the hammer marks 
I'd previously noted on the seal-carrier  was responsible for a bulge on 
the back side of it where it mates with the block, which probably was 
keeping the o-ring from being able to seal it against the block;  I 
replaced the carrier with one from an older 1.6 NA engine and put a new 
o-ring and seal on it.

After warming up the exhaust shows no smoke, I'm surprised - also can't 
see any smoke just trying it out on the steep dirt and gravel road in 
the little holler I'm in so I guess I'm ready to put it back on the 
road  and hopefully park the van for awhile.  I've yet to check the 
timing on the IP yet, but am hoping it's close enough to run for awhile, 
until I can get familiar with that procedure and possibly use what I 
have laying around to take the measurement with.  Thanks to you all who 
provided helpful suggestions and moral support, and best wishes for a 
prosperous new year.

Mike in NC