Date: Thu, 6 Sep 2001 10:36:49 -0400
Reply-To: dieselwesty <dieselwesty@YAHOO.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: dieselwesty <dieselwesty@YAHOO.COM>
Subject: Re: [DIESEL] RE: Question about HAMMERING, new 1.9l NA motor,
today
Content-Type: text/plain; charset="iso-8859-1"
Thanks Sandy for the response.
As Ken Hunter is the only other person that I have met on this list that has
the EXACT setup as what I am attempting to do, he said "I had to mess around
a little by
slipping the belt on the pump sprocket a tooth off so it would line up w/TDC
and still fit the pin in the hole. My pump is red dot not yellow dot. I read
yellow dot can take more advance".
I am pretty sure that is what we also had to do yesterday. There are NO
questions in finding the timing marks on fly wheel, pump sprocket to pump
and cam. You use the flywheel and clutch plate from your 1.6l motor on this
installation as well. The 1.6l head is about 3/4 of an inch taller then the
mechanical old style 1.6l head, so I am guessing that is what is setting
things off by a tooth.
You do use a standard 1.6l belt and a different intermediate pulley that is
smaller and allow you to use the 1.6l timing belt and your 1.6l timing belt
steel cover.
So I am convinced I have too much advance, I will back of to 1.00 mm on
stroke from the 1.03, but I do not think that is enough to get ride of the
hammering?
Thanks again I will let you know. Right now we are trying to find an air
leak that is causing #1 injector to not open or a clogged injector. That is
a nasty sound and I figured my engine was TOAST.
Bryan Belman Pt. Pleasant, NJ
1990 Audi 200 Turbo (Money Pit)
1982 Westy 1.9l NA (In process)
1970 Type1 Std. Beetle (This one is done)
----- Original Message -----
From: "Sandy Cameron" <scameron@compmore.net>
To: <diesel@vwfans.com>
Sent: Wednesday, September 05, 2001 11:36 PM
Subject: Re: [DIESEL] RE: Question about HAMMERING, new 1.9l NA motor, today
> At 06:29 PM 9/5/01 -0700, you wrote:
>
> >We could not insert the timing pin and get the motor
> >to TDC when installing the timing belt.
> >My mechanic, who has worked on many VW diesels, but I
> >would say is not a total expert, said that is OK that
> >we were not able to get the pin in and everything to
> >TDC.
>
> I've never seen one where, with the flywheel at TDC, the pin would not go
in
> to the sprocket.
>
> Sometimes one makes the mistake of not getting the actual TDC mark lined
up
> with the pointer in the hole. The TDC mark on the flywheel is a small V
> grove machined into the edge of the casting on a slant. There are usually
2
> cast "Bosses", one on each side of the V shaped groove, and sometimes
people
> will try to line up with one of these. Is it possible on the 1.9, that
there
> might be an advance timing mark as well? I just checked my red bentley,
and
> it looks the same as for the 1.6
>
> Could the 1.9 head be a little taller than the 1.6? the distance from the
> head mating surface to the camshaft center is crucial to the timing belt
> position.
> This could require a unique belt for the 1.9.
>
> On the pump sprocket, there is a fine notch or line engraved on the rear
> edge of the rim facing the pump. When properly timed, this will be
vertical
> at the top, and match a similar line on the pump mounting plate. At this
> point, you should be able to get the timing pin in.
> I would say it is imperative that the pump sprocket be pinned, and with
the
> cam sprocket loose so it can free-wheel on the shaft,turn the engine to
TDC
> and if the belt is not right, (slack only at the idler) shift 1 tooth fore
> or aft to make it right.
>
> Bently says, ensure all slack in the belt is at the tensioner. If not, you
> may be out by one tooth. If this is the case, your valves may be kissing
the
> tops of the pistons, making the noise you hear. This would be a camshaft
> timing problem, not a pump timing problem. You ARE resetting the cam
timing
> as specified, aren't you?
> I would for sure, re-set the pump and cam timing until it lines up as
> specified. Nothing else should be accepted
> I had an engine that had dimpled pistons, presumably from being one tooth
> off on the cam.
> Didn't seem to hurt it, but there were permanent marks on the top of
pistons
> 1 and 4.
>
> Once you have made the TDC mark happy with the pump pinned, then shove
the
> timing plate in the back end of the cam and tighten the cam bolt,(holding
> the sprocket with an appropriate bar to absorb the torque so it's not
> applied to the cam shaft and plate)
>
> It's always worked for me, there's no real trick to it.
>
> Sandy
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