Date:         Wed, 18 Aug 2004 08:56:29 -0400
Reply-To:     Tom Miller <tmiller@VCMAILS.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Tom Miller <tmiller@VCMAILS.COM>
Subject:      Re: diesel injection pump timing
Comments: To: Alex Towner <altowner@COMCAST.NET>
Content-Type: text/plain; charset="iso-8859-1"

Before you jump off the deep end, make sure your glow plugs are getting
power.  The engine should start even with the timing off but if the glow
plugs are not working, it will not go.

The Bentley manual is correct.  If you followed that, there is nothing more
to do with the timing.  Just make sure #1 cylinder is near TDC when you set
the timing, and the timing mark is visible on the flywheel.  That way, you
know the timing belt is on correctly.  I usually hand crank the engine a
couple of revolutions to make sure the valves clear the pistons before I
start the engine.  A couple of teeth off on the timing belt position is all
it takes to bend the valves!

TEMiller

----- Original Message -----
From: "Alex Towner" <altowner@COMCAST.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Wednesday, August 18, 2004 1:57 AM
Subject: diesel injection pump timing


Question:

From:    Kenneth Wilford <kenwilfy@COMCAST.NET>
Subject: Diesel Vanagon Timing Advice

I love the waterboxer engine.  No timing belt.  On the diesel VWs it is a
different story.  I have all of the tools to time the diesel Vanagon but I
have never really figured out exactly how to do it.  Can anyone help me with
this?  I put a new belt on and set the timing right that way (per Bentley).

Right now I am just trying to get the injector pump timing right.  I have
the dial indicator but I am not sure I am using it correctly.  Anyone with
experience in timing diesel VW injector pumps, please share your wisdom with
me.  I can't get the van to start and I think it is the pump timing that is
not on the money.

Any advice would be greatly appreciated.


Reply:

Ken,

Even if you didn't set the diesel pump timing with the dial indicator at
all, the van should start.

Double-check your belt installation - be sure all of the marks line up.
Exactly follow the Bentley, particularly with respects to loosening the cam
sprocket while lining up and tensioning the belt. Tighten the cam sprocket
last. Turn the engine at least 2 full revolutions before starting to be sure
nothing hits. A diesel belt that is off only 3 teeth can cause valve to
piston contact.

***Be sure that the mark on the sprocket for the injection pump is lined up
with the mark on the support bracket. I learned the hard way that it is
possible to set the pump 180 degrees out of phase. If it is 180 degrees off,
it will cause a no start condition, or it may only start with the throttle
depressed substantially.***

As for setting the pump:
- Set the engine at TDC by looking at the flywheel.
- Remove the bolt between the injector lines on the pump and insert the dial
indicator.
- Loosen the collar on the indicator and push the stem in 2-3 mm as shown on
the dial. Tighten the collar.
- Rotate the engine backward until the gauge stops moving.
- Set the gauge to zero.
- Rotate the engine forward (clockwise as you face it), and stop dead on
TDC.
- The gauge will show your injection timing.
- Loosen the pump on its bracket and rotate it until the gauge reads the
value you want.
- Tighten the pump on its bracket and repeat the engine rotating proceedure
to confirm that your adjustment stayed in place. It might take a few tries.

***Another possible reason for a no start condition is that you have bumped
the wire on the start / stop solenoid on top of the pump. Confirm that it
has voltage when the key is turned. The solenoids can fail; I had one stick
in the "on" position - I couldn't shut off the car. I had to deliberately
stall it to kill the engine. Interestingly this happened right after the car
had a timing belt change and had been sitting for a couple of months -
probably the same in your case.***

Good luck.

-Alex
'85 with 2.0 inline