Date: Sun, 20 Jun 2004 14:33:51 -0400
Reply-To: Doug Fitz-Randolph <fitzr@SUSCOM-MAINE.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Doug Fitz-Randolph <fitzr@SUSCOM-MAINE.NET>
Subject: Re: Finding TDC on I-4 Conversion, 1.9TD @ 15 degrees
In-Reply-To: <AIEFIGCNNANNIHLNFBPEOEGDIDAA.vanagon@volkswagen.org>
Content-Type: text/plain; charset="us-ascii"
Talk about procrastinating... ONE YEAR LATER I'm finally getting to this!
Found the access hole no prob - was looking in the wrong place.
Symptom: Last spring, my injection timing started to retard. At first I
could get the engine to run by leaving the cold start knob pulled out all
the time, but eventually that stopped working and the engine would not run
at all. This very gradually, getting progressively worse in a linear fashion
over the course of about 50 miles.
Suspicion: Several people suggested the cam sprocket had sheared off the key
and begun to rotate on the shaft. Today I'm checking to see if this is the
case.
Checking: With the timing belt in place, I locked the camshaft using the
locking plate, and the injection pump sprocket with the locking pin. When I
look at the KEP flywheel through the access hole, I can see the TDC mark.
Here's where I'm a little unsure, though. With no tension on the belt, the
mark is at the very bottom of the access hole, just coming into view. If I
apply a little tension to the belt by using a socket wrench on the camshaft,
I can get the mark to be square in the middle of the hole. If I let off the
tension the TDC mark stays put. If I apply a little more tension, I can get
the 3 degree mark to appear. Letting off the tension it returns just about
to having the TDC mark square in the middle.
Question: Being a degree or two off would seem like it's a big deal to me,
so this has to be pretty precise, right? My question is - how precise?
Should the mark be aligned with tension on the belt? How much? Also, this
seems like it's nearly right on... like if the cam sprocket had slipped it
would have been further off than this very small amount of +- tolerance
depending on belt tension.
Your input/advise is greatly appreciated!!
Doug Fitz-Randolph
Freeport, ME
-----Original Message-----
From: David Marshall [mailto:vanagon@volkswagen.org]
Sent: Wednesday, June 11, 2003 9:52 PM
To: Doug Fitz-Randolph; vanagon@GERRY.VANAGON.COM
Subject: RE: Finding TDC on I-4 Conversion, 1.9TD @ 15 degrees
Doug and the list.
I was away for a few days so I am sorry for the not so speedy reply on the
question.
All KEP I4 adapter plates have a small 1/2"(ish) hole on the exhaust side of
the motor - this hole has a neat shiny cover to it that can be pried out
with a small knife or a screw driver.
The I4 flywheels can only go on one way - I have never seen the timing marks
off using KEP stuff (the original VW stuff yes!).
The *absolute* best way to verify that you are indeed at TDC is to remove
the injector and put the eraser end of a pencil down there or softlike that
and verify by feel that the TDC mark really is TDC. As I have said, the KEP
stuff that I have worked with has always been 100%
David Marshall
Fast Forward Automotive Inc.
4356 Quesnel-Hixon Road
Quesnel BC Canada V2J 6Z3
http://www.fastforward.ca mailto:sales@fastforward.ca
Phone: (250) 992 7775 FAX: (250) 992 1160
- Vanagon Accessories and Engine Conversions
- Vanagon, Transporter and Iltis Sales and Importation
- European Lighting for most Volkswagen models
Due to the large volume of email we receive, PLEASE include previous
emails when responding. This will allow us to read the complete dialogue
in one message and will result in quicker and more accurate responses.
-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com]On Behalf
Of Doug Fitz-Randolph
Sent: June 11, 2003 9:07 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Finding TDC on I-4 Conversion, 1.9TD @ 15 degrees
Huh. I wasn't able to find any hole, but maybe I missed it. I didn't install
this myself. The flywheel is the one that come w/ the Fast Forward kit I'm
assuming - don't know 100% for sure. If in fact the hole does exist and I
can find the marks on the flywheel... is there a possibility that it still
might not be TDC, i.e. the flywheel was not correctly oriented when
installed? I'm unfortunately not too familiar with that end of the engine.
Thanks,
Doug
-----Original Message-----
From: mark drillock [mailto:drillock@earthlink.net]
Sent: Wednesday, June 11, 2003 11:58 AM
To: Doug Fitz-Randolph
Cc: vanagon@GERRY.VANAGON.COM
Subject: Re: Finding TDC on I-4 Conversion, 1.9TD @ 15 degrees
Good question. What flywheel are you using?
The KEP flywheel has marks and the 15 degree adapter a hole that I
assume lines up with the marks when the engine is a TDC. I have not
installed the parts to verify this. The mark is on the back face of the
FW. I specified a 15 degree diesel kit when I ordered from KEP.
Mark
Doug Fitz-Randolph wrote:
>
> I'm stumped. How do I get TDC? No access hole I can find, and not the
> original flywheel anyhow I think. Do I need to remove the head to find it,
> and then perhaps make my own access port and some sort of reference mark
for
> future use? Just beginning to set injection pump timing and can't get
> anywhere without TDC.
> Thanks!
> Doug Fitz-Randolph
> Freeport, ME