Club 80-90 Forums

Getting my 1y ready to plant in my crew cab, decided to change timing belt, sliped the old belt so timing lost how do I find tdc without gear box on ? and how to I align cam ?
cheers

neil

Hope this helps ( From a Previous Post ) You dont need to use the DTI if you are OK with the marks or line up holes on your pump pulley, good luck.

Hope this helps............
http://www.vwdieselparts.com/injtim.htm" onclick="window.open(this.href);return false;

When I did mine I used a standard engineers DTI with a magnetic base, this is OK but you must find a convenient place to clamp the base to. I actually removed the base and used the threaded end and used 2 nuts on the throttle cable bracket. Also I could not find the TDC mark on the flywheel so I removed an injector and inserted a soft stiffy bit of wire and fealt TDC.

Good luck
Oh just found another one, not boring you now I hope

http://www.oneilcastro.com/A2Bentley/FU02/ch5.5.3.html" onclick="window.open(this.href);return false;

When you do your timing................

You should be OK and use the TDC mark on the clutch looking through the plastic bunged peephole but this is what I did..........

Remove No.1 injector and using a bit of soft bent wire poke it in the hole and turn crank till you can "feel" top dead centre.
On the end of the camshaft there is a slot, fit a nice fitting bit of bar in this slot and this will hold the camshaft in the right place..........both cam lobes should be pointing up, both valves on No.1 closed.
Are you still with me ?
So now you have No.1 piston TDC (I could not find the marks on the flywheel so I think this way is better anyway) and both valves on No.1 closed.
Now then, line the hole in the injection pulley up with the hole in the pump casing, I think it was a 6mm drill I then inserted in the hole to keep it lined up.
Everything is now in the right place to fit your new belt AND TENSIONER.
With ya new belt on and tensioned nicely spanner the engine over a couple of turns and recheck your marks..........there ya go........seemples.
If your injection pump pulley has been shifted on the three slotted holes you will need to do the injection timing as per attatched links.
Cheers. Pete

Thanks Pete will give it a go

How did it go Neil ?

Pete

Been a bit layed up with a bad back, however made couple of bits of tooling ie cam locking tool (4.50mm thick for ref ) also made pump locking spigot. All making sense now, some previous tippex marks lining up now,confirming tooling ! Another question ! actuator arm on pump of 1.9 different than 1.6. Remove 1.9 actuator arm, 1.6 arm is not a direct fit.

Question is do I

A ) Stick with the 1.9 actator arm assembly

B) Modify the 1.6 actuator arm to fit the 1.9 pump

C) Change the top plate assembly from the 1.6 onto the 1.9

D) Any better ideas and what to do !

Cheers neil

Must admit I cheated a bit here. Removed the original and set it down so it cleared the engine lid and I think I moved the anchor point for the cable a bit lower, oh yes I remember now, it originally had a damper on the linkage and thats what I removed and where I fitted the cable, then hacksawed off the original cable arm. Jesus hope this makes a bit of sense.

Nice one Pete, Think I'm gona change over top plate assembly, will let you know how it goes !
cheers
Neil

Pete

Changed lever mech within top of injection pump, through spindle from cs was slightly longer, thus able to fit original CS lever, hope it works !

Neil

Good, I reckon this job has been done 101 ways. As long as you gat full travel. Well done mate, vroom vroom

E D I T E D I T..............got not gat !