[Vwdiesel] Setting Timing Problem - 1982 Diesel Rabbit

[82 Diesel Westy]

Sounds like you KNOW what you are doing.  My first
guess is the timing mark on the fly wheel is not what
you think it is, try looking for another mark maybe.
Everything else you did sounds Good.
With the motor on this mark, make sure #1 piston is at
TDC.

Humm
Bryan


--- Doug Presny <DPresny at cleantechpartners.org> wrote:

> I have completed the timing process using the
> procedure below.  My problem is that when I rotate
> the crankshaft 1/4 turn with a socket wrench,
> something is stopping the rotation (piston on
> valve?).  I make the rotation very gentle, and have
> not tried to put any real force on the rotation for
> fear that I will damage something.  Any guidance is
> appreciated.  I highlighted two steps that may have
> introduced trouble.  Manual transmission is in
> neutral.
>  
> 1982 VW Rabbit, 460 494 077 Bosch Pump (specs either
> .88 or .93 +- .02 from recent table)
>  
> a) Needed to replace passenger side and front motor
> mounts.
> b) Purchased timing tools.
> c) Drove car into garage with engine running fine -
> my daily driver.
> d) Removed timing belt and injection pump.
> e) MOVED CRANK UNKNOWN AMOUNT WHILE REMOVING
> CRANKSHAFT PULLEY.
> f) Replaced motor mounts.
> g) NEEDED TO LOOSEN STARTER BOLTS TO REMOVE FRONT
> MOTOR MOUNT BRACKET.
>  
> Timing Process
> h) Cam lobes for #1 were already up, so almost no
> movement of cam to insert locking tool.
> i) Inserted locking pin in injection pump with
> sprocket aligned with bracket mark.
> j) Aligned the flywheel timing mark with bell
> housing arrow (mark was two lines " II " on
> flywheel).
> k) Put timing belt on all sprockets and tightened
> belt.
> l) Removed locking tools.
> m) Rotated crank counter clockwise until preloaded
> gauge quit moving.
> n) Zeroed gauge.
> o) Rotated crank clockwise until timing mark aligned
> with bell housing arrow.
> p) Gauge reads 0.024 inches which is equal to 0.93
> mm. - on spec
> q) Repeated m through p to verify reading.
> r) When attempting to rotate the crankshaft clock
> wise two revolutions by hand to ensure no troubles
> and to check tension on timing belt, I run into what
> feels like metal hitting metal.  I reversed the
> rotation and the same thing happens 1/4 turn in the
> other direction.  I tried both directions several
> times and the "stops" are still there.
>  
> My hope is that someone has run into this before and
> can help me identify and recover from my error.
> Thanks - Doug
>  
>  
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