Timing belt procedure

[Vodim]

Is this really what the TDC mark on the flywheel is supposed to look like? In the pictures and videos I’ve seen, the mark always seems much clearer and more distinct. On mine, it just looks like a small radiused notch in the edge of the flywheel. Is this definitely the TDC mark?


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[mioba]

Yes. On. wither side you get an upward facing not ch

[Vodim]

Cheers, feels good to have that confirmed.

I’ll continue changing the belt tomorrow. Next up is loosening the camshaft sprocket bolt, as there was a slight discrepancy between the camshaft position and the TDC mark, as I mentioned earlier.

However, a colleague suggested that before I do that, I could fit the new belt, tension it and see if that alone brings everything back into alignment. I guess his thinking is that wear or stretching of the old belt might account for the discrepancy, and that a new, properly tensioned belt could put everything back where it should be.

Could there be any truth to that?

[clift_d]

I wouldn’t have thought so - you might be able to use the old timing to shortcut a rough alignment but consensus seems to be that the cam sprocket should be loosened and alignment checked for it to be properly dialled in.

There’s more info in this the first page of this samba thread:

https://www.thesamba.com/vw/forum/view ... 9a5032fb7e

[mioba]

Loosen the camshaft bolt.

1/2 a tooth off and the belt is a bitch to fit.

The belts don't stretch. they get old which compromises the stregth. If they stretch you have valved hitting pistons. So ignore the comments of your contact.

Do NOT use the camshaft lock to lock the camshaft to remove the bolt (45nm)

You need to make a tool to hold the sprocket.

There are loads of good vids for the entire procedure on YT with older golfs that had a near on identical engine.

Mage sure you have a new tensioner.

when all buttoned up. Give the crank a couple of turns to make sure its all moving.

Crank at TDC, fuel pump at TDC then camsgaft at TDC.

If the cam is near on when getting it to TDC you can use pipe wrench to turn it a tad to get it perfect. Use it between the lifters well wrapped.

Just take your time. You got this.

[Vodim]

Thank you guys!

Got the belt changed and the injection pump timed in. However, with everything put back in place it won’t start. It’s cranking (is that the word?) but does not start. Could it be air in the system as I have worked on the pump?

[colinthefox]

Two possibilities that I can think of.
1 That the crank is correctly timed but exactly 1 revolution out.
2 That you have introduced air into the diesel injection system by for instance loosening the connections. I think these pumps may be self priming, but might take some time and flatten the battery. Slacken the injection pipe connection to at least three of the injectors, and crank with throttle wide open until diesel free of bubbles comes out, then tighten and it should start.

[clift_d]

Also, check you haven’t accidentally disconnected the stop solenoid on the injection pump.

[Vodim]

It was air in the system. Primed the pump and loosened the injectors until diesel appeared and then tightened. Then it started perfectly.

Also took a short ride just now and everything seems fine. In the beginning there was smoke coming from engine so was a bit worried. But it stopped after a while so I think it was just oil and diesel spill.

Really happy to have pulled this off. A year ago I had never done more than changing oil and filter on cars. Many many thanks for all the help!!