Club 80-90 Forums

Hi,

Ive recently replaced the head gasket on my 1.6d jp engine, i have refitted everything bar the timing belt. unfortunaltly there are a few areas i am unsure of and would be grateful of some assitance.

I have read the haynes manual and set the engine to top dead centre but cant seem to work out the required position of the camshaft,
and also the diesel pump has 2 black dots on the pulley in 2 different places and i am unsure which is the correct position.

Any help would be grateful

Rich

here ya go Rich, hope it helps,


https://club8090.co.uk/forum/viewtopic.php?f=12&t=71379" onclick="window.open(this.href);return false;

Where abouts in the world are you ? Sometimes if a T25er lives nearby he may well pop over and give you a hand

Hi pete,

Cheers for that i'm down in swansea,

in the haynes manual it doesnt mention using a guage to set the injection pump, it says you should alighn the wheel with a marking on the pump, I can see a mark on the pump, but there are 2 on the wheel.
As i dont have a guage it would be much easier if this was the case, but if not ill have to pick 1 up.



Rich

Look in Wiki I found it really helpful, I think you put a bolt in a hole on the pump and a bar across the cam, but it is all explained there.

As pete says to set the timing precisely you will need a DTI gauge, I have just done my JP today.
I think the method you mension is a rough guide.
Did you do the conversion yourself or was it already in there?
The reason I ask is I do not seem to have any marks on my pump wheel as far as I can see only the smaller hole for a timing pin. What Haynes manual are you using?
Is your manual JP specific? I'm using one for the diesel golf & Jetta which referes to the DTi guage.
When using the camshaft locking tool make sure you take up the slack either side with a pair of feeler guages, as without them when the belt is fitted the crankshaft can be moved 10mm even with the locking tool in place.
Rob.

Perhaps I was a bit "deep" with the DTI thing. As you stated that you have removed the belt I think you should be safe enough to just go by the settings and locking pins in holes.
Top dead centre mark is not on the flywheel as it is on the clutch itself OR stiff wire with the injector out and feel TDC.

Looking at the slot in the end of the camshaft, find a nice fitting piece of flat bar and then with the two cam lobes sticking up, both valves on No.1 will be closed...still with me ? Fit your bar in the slot and pack out the difference between the bar and rocker box on either side of the camshaft.

So now you have No.1 cylinder TDC
Camshaft in the right place and locked (both valves on No.1 cylinder are closed)
Now to your pump whichever setup you have, some are adjusted by moving the whole pump and some by adjustment on the pump pulley. In your position without the DTI and bits I think you will have to trust that the timing was OK before you carried out the repairs.
Have you got a hole in the pump pulley ? Hope thats a yes. This hole lines up with a hole in the pump casing, insert a good fitting drill in the hole.

Everything is now in place to fit your belt AND NEW TENSIONER. Fit and tension the belt, remove all your locking pins and bars and spanner the engine over a few times. Line everything up again and check all the settings....TDC, Camshaft and pump locking pin, all good ?
Put it all back together and presto VROOM VROOM !

Good luck, I will keep me eye on this Forum during the next couple of days (cant go camping, wife working) and look for a smilie

Hi,

Thanks for the help, all sorted.

Very welcome, enjoy it ! When you make your next step...........upgrading to a 1.9 1Y give us a shout.