[Vwdiesel] Setting Timing Problem - 1982 Diesel Rabbit

[MLightner]

>
>Message: 8
>Date: Fri, 12 Jan 2007 09:45:01 -0600
>From: "Doug Presny" <DPresny at cleantechpartners.org>
>Subject: [Vwdiesel] Setting Timing Problem - 1982 Diesel Rabbit
>To: <vwdiesel at vwfans.com>
>Message-ID: <20A2557E4F8C3B48A3F6158A4A280A49146AE8 at CTT001.ctt.local>
>Content-Type: text/plain;	charset="iso-8859-1"
>
>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
>  
>

I think your 'inches to mm' conversion is off - I make that to be .6 mm