Wobble's Gone, But Engine's Unhappy

[Kneale Brownson]

:cry:

The pulley wobble that started me on the investigation of my new-to-me 1994 Jetta TD's timing belt has been cured, but the engine isn't running well and smokes a lot.

After getting the crankshaft pulley off, I found it was in fine shape and the crankshaft itself was undamaged, so I guess the wobble was the vibration damper I replaced.

Anyway, after closing everything back up, I had a heck of a time getting the engine to start.  Had to crank repeatedly, tried with the cold engine knob pulled fully out and with it pushed in (ambient air temperature today was around 85 degrees F), with some accelerator pedal pressure and without, etc.  It would almost catch and then not.  Finally started and ran for a few seconds and then died.  After that, I used the cold engine knob and a depressed pedal and finally got it running.  It would die at an idle until I kept it around 2K RPMs long enough for the coolant to warm up, and then it would idle roughly, but I could get out and look at the pulley to determine that it's running smoothly.  Hooray for that part!!

So now, I have a rough, surging idle that smooths out with revs--engine revs easily, etc.  But it smokes terribly.  I had so much smoke going out my barn doors that the neighbor dashed over thinking I had a fire or something.    The car has smoked upon startup since I've had it, but the smoking cleared up once fully warmed and only reappeared under heavy acceleration.

When I put the timing belt back on, I made sure I had the TDC mark in the bellhousing window correctly and the cam locked in the TDC position it was in when I took the belt off.   I left the injection pump pulley lock in place and had the cam pulley loose until I got the belt back on and then snugged and torqued (with my homemade cam pulley lock in place) the cam pulley bolt.  I took the cam lock off while torquing the bolt.  I removed the injection pump lock and cycled the engine a couple times by turning the crankshaft bolt and checked that the cam lock would go back on while I could see the tdc mark in the bellhousing, and then I tensioned the belt per Bentley with the VW210 gauge.

Any guess why the engine now has a surging idle and has become the neighborhood insect repeller?

[jtanguay]

I took the cam lock off while torquing the bolt.

shouldn't the cam lock be left on while torquing that bolt??? my understanding of what would have happened, is that the torque would have been transfered to the belt, and thus whatever else the belt is attached to (ie: injection pump) while the cam is free to move.

best bet, is to try re-torquing with the cam locking plate, and hope that she purrs

[Kneale Brownson]

I understood it was not a good idea to torque (or untorque for that matter) the camshaft pulley bolt with the locker tool in place because that was a good way to break off the end of the camshaft.  This posting describes what happens:  http://vwdiesel.net/phpBB/viewtopic.php?t=9986

Instead, I had a locker tool I made that held the camshaft pulley still while the bolt was loosened and/or tightened to torque specs.  The shaft itself turned maybe half a tooth when I took the bolt out originally, and I didn't see any movement while I was torquing the bolt.

The bottom of page 2 of this posting shows my home-made cam sprocket locker tool:  http://vwdiesel.net/phpBB/viewtopic.php?t=10019

I guess I'll take the valve cover off and recheck the timing marks tomorrow.

[jtanguay]

oh well as long as the cam sprocket was held down when torquing...  did you re-check the cam to make sure that it didn't move after you torqued it?

[Kneale Brownson]

I THOUGHT I rechecked after tightening the cam pulley bolt, but I may not have.  I'm going to check the timing alignment today.

[jtanguay]

I THOUGHT I rechecked after tightening the cam pulley bolt, but I may not have.  I'm going to check the timing alignment today.

always good to re-check things  hopefully thats the problem.

[Kneale Brownson]

I'm told I need to do the static test of the injection pump to get that timed right since the cam and crank are in time and it's running so poorly.

So I dug out the 2066 tool I purchased for that task and tried all of the several dial indicators I have here, and none will work with the tool.  Not only that, nobody in TC, MI, carries a supply of dial indicators and none of the tool catalogs I spent way too much time looking through today has all the specs needed to determine the indicator will fit the 2066.

Does anyone have the tool with indicator who can find a product number and brand for the indicator so I'd know for certain which one would fit?  Or does anyone know where I can just plain order a proper dial indicator for the 2066?

[jimfoo]

http://www.volkswaparts.com/VWDieselDialGauge.htm

[Kneale Brownson]

Thanks, Jim.  I already have the tool, just need the gauge.  But I've found one that's supposed to be on the way now.