[Vwdiesel] Setting Timing Problem - 1982 Diesel Rabbit

[David Cook]

If you are rotating the crank without the belt, then
the camshaft isn't moving, so yes you are likely
touching a piston and valve.

I had to do this one time.  All you have to do is
loosen the nuts on top of the camshaft holders so it
is loose.  The camshaft will lift up and allow all the
valves to close.  Then you can rotate the crank to the
proper position.

Once the crank is set, rotate the camshaft to the
proper position (or close to it) then carefully
tighten the nuts.  Kind of spread it over the lenth of
the shaft to avoid damaging it.  (Tighten one or two a
bit, then move further down the shaft to another one,
etc.  Don't tighten the first nuts all the way before
moving to the next ones.  Kind of like bolting a head
down.)

David

--- 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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> Vwdiesel at vwfans.com
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> 


David Cook
Red '86 Cabriolet Diesel Powered
Red '90 g60 Corrado 
Brown and White '78 Westy Campmobile "Bear"
and others in various states of disrepair
Pictures here: community.webshots.com/user/superdave5599


 
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