Date:         Mon, 26 Sep 2011 20:29:31 -0700
Reply-To:     Jim Arnott <jrasite@EONI.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Jim Arnott <jrasite@EONI.COM>
Subject:      Re: Timing belt replacement and valve timing in VW gas and Diesel
              engines
Comments: To: Poppie Jagersand <poppie.jagersand@YAHOO.CA>
Comments: cc: Diesel Vanagon <Diesel-Vanagon@yahoogroups.com>
In-Reply-To:  <1317091199.56431.YahooMailNeo@web45311.mail.sp1.yahoo.com>
Content-Type: text/plain; charset=US-ASCII; format=flowed; delsp=yes

IMHO, you're overthinking it. The only problem here is that the cam is
out of time. (Not an issue on the gas motor because the cam is keyed
to the gear. On the diesel it's not.)

Diesel:

You have the correct tools to time the motor, use them.

Set to near TDC.
Insert cam locking plate. (If you shim it like it says in the manual,
it will have less tendency to end up on the ground.)
Pin the pump.
Loosen the cam gear bolt (DO NOT use the lock plate to hold the cam
for loosening this fastener! I use a 12" 3/8 drive extension through
the cam gear hole and lever to the head) and smack the cam gear with a
dead blow hammer to loosen the taper.
Install belt.
Load tensioner.
Snug cam gear.
Loosen (3) bolts holding pump.
Set timing.
Rotate engine by hand at least (2) revolutions. Stop at #1 TDC.
Check cam and pump timing.
Okay? If not, adjust.
Lather, rinse, repeat.
When timing is correct and the lock plate fits while at TDC, torque
cam bolt (Note: I found that the factory ~30 lbs ft torque spec is not
adequate. I torque mine to 50 lbs ft. You choose what works for you.
DO NOT use the lock plate to hold the cam for torquing this fastener!)
Button it up.

That's how I do it.  Every single time. Takes about an hour. Until you
have to replace a head ($300) because the timing came undone, it's a
PITA. After that, it's easy. Based on my experience, $300/hour is
pretty good wages.

Jim

On Sep 26, 2011, at 7:39 PM, Poppie Jagersand wrote:

> Note on the apparent misalignment of the engine between the flywheel
> TDC mark and the valve and injection pump lock positions:
>
> 6mm off on the flywheel diametre of 210mm is 6/(210*pi) = 0.009 or
> 0.9% of a revolution, 3.3degrees.
>
> I counted 22 teeth on the crank pulley. If I were to move the belt 1
> tooth forward to would mean a 16 degree change. That is way too much.
>
> By leaving it as is, if the flywheel mark is indeed correct I would
> be running with injection pump reference and valve timing is 3.5
> degrees retarded compared to flywheel (and presumably cylinders).