Date:         Tue, 10 Aug 1999 00:43:27 +0000
Reply-To:     Martin Kennelly <korn@SIMNET.IS>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Martin Kennelly <korn@SIMNET.IS>
Subject:      Re: 1,6TDSL changing engine drive belt
Content-Type: text/plain; charset=us-ascii

Yes it is possible to do this job without the need to buy any special
tools and obtain as close to perfect timing as makes no difference.
Having a patient helper who you can assist when needed is a luxury.
You will note from the Bentley  13.20 and 23.3  that you need to turn the
engine to tdc the cam and lock the pump and line up the flywheel notch .

First "rotate the engine until the cam  lobe cyl. one points upwards".
Then you can observe that a suitably thick plate can be inserted onto the
the other side of the cam and locked so that the cam will not move.
 Line up the notch on the flywheel to a visible mark that you can see
through the peephole with the aid of a long flexible neck and a flashlight.
Then you need to lock the pump sprocket, use a bolt  about 7 cm long and
exactly 1.6cm thick, it exactly fits in the hole on the sprocket ,
locking it to the block.

The pump is now locked,  Then you have to lock the cam, The easiest way
is to have a helper ( of any age and any intelligence) to wedge the
thick plate and keep it in place ( it can pop out ).I used a thick
galvanized plate cut into a suitable shape and drilled two holes into it
 so that I could secure it  into the head using the cam cover bolts.
Even so what ever you use has to be wedged in for extra security.
Then you can loosen the cam sprocket nut, and give the sprocket a whack
with a rubber hammer in order to loosen it.
You then check the flywheel alignment, the notches on the pump sprocket
wheel and of course the cam. Put on the new belt and tension it, not too
tight not too lose. You should be able to obtain almost perfect timing
to within a half of a  pump sprocket wheel tooth.
if you are not entirely happy with the timing, re smoke, noise and
performance the you can get the professional to use a gauge for the
final adjustment to the pump timing.

What does the sl  stand for. ( 1.6tdsl)   - slow? slouch? steal?

Good luck, Martin Kennelly

>
> I surf through archives but don't found any comments or tips about changing the drive belt of 1,6 TDSL engine.
>
> Is it possible to do this job without mass of special tools (according to Bentley manual chapters 13 and 23).  The tension of
> belt and valve and injection timing must be correct.  Are there any common ways (and tools) to do that job?  I'm gonna
> change tension roll with belt.  The official service steals you $400 for that job!!
>
> Regards, Juha Koivisto
> 88 Vanagon (Bus) 1,6 TDSL
>