HELP! Timing Belt issue and now over my head.

[BigD]

91 TDI.  Needed to change my coolant pump.  Books LIE!!  Bigger job than I thought.  "remove timing cover.  Remove crank pulley.  Remove water pump pulley, remove hoses, remove 4 bolts holding pump housing to engine, remove 9 bolts and separate water pump from housing reverse for install."  Not even close!!  Needed to remove alternator, NP. Hoewver, the 4 bolts that hold the water pump on also hold the slternaotr bracket on.  In order to get those out I needed to remove the alternator.  Then discovered that the 2 top mounts were unaccessible being covered up by the fuel injector pump.  Okay, change tactics, since it is the water pump shaft leaking, just change the pump and leave the housing in place.  Now, remove timing belt because imtermediate shaft pulley is blocking the screws.  Not a big deal because I need to change the timing belt anyway.  Okay, remove inspection plug on transmission bellhousing, trun crank until marks line up to give me TDC.  Removed timing belt, removed intermediate shaft pulley, removed water pump amd replaced.  Success!!  Now I moved to the timing belt installation, removed valve cover, checked cam end for alignment tool insertion and it is BELOW the end of the head, no way to insert the tool.  PANIC!!!  I have NEVER done this on a VW before!!  Okay, stepped back and looked close, the alignment hole where the locking pin for the injector pump goes is also on the other side of the pump.  It looks, to my inexperienced eye, that I am 180 degrees out.  If this is so, can I reinstall the belt and crank the engine around again until the marks line up?  Somebody with knowledge, please say yes.  I have already re-installed the intermediate shaft and the belt.  Since I never touched the tensioner and kept the belt fight to the next tooth, I think I can save this.  Otherwise, do I have to pull the head and the pump start over from scratch?  There is really nothing wrong with this engine, but since I am the 3rd owner in 5 years and, even though the belt looked good, (I just rolled 400K and have always been told  (with my 85 Golf, that it should be changed every 100K)  I decided to change it so that I would KNOW for sure.  HELP!?!

[jackbombay]

  Pull the head? Did you have the head off?

  With the crank at TDC the #1 cylinder cam lobes are not both pointing up?

  Thats what you want, crank at TDC and both #1 lobes pointing up.

[Vincent Waldon]

Here's some pictures that may help:

http://vincewaldon.com/index.php?option=com_content&task=view&id=24&Itemid=28

[steve6]

re the water pump 4 bolts for the housing... I came across this... I struggled for hours to get the right top side out.. left top side was easy with a universal.. eventually got it loosened with a modified wrench... no way I was taking the pump off though.

what did i do to tighten it after install? I cut the bracket about a inch in and 2 or three inches down on that side with a mini grinder... socket on a extension went right on now... I did another car after this and cut the bracket BEFORE removal of the bolt.... just gotta be careful, its close to the IP.

I was extremely glad I modified the bracket after cause the aftermarket pump i put on went bad... and had to change it again.

I couldn't figure out why I didn't see others having this trouble, not sure what others do 

[smutts]

Ref: that gitting bolt hiding behind the injection pump. It is almost easy with "half moon" or "crescent" spanners, nigh impossible without. 

[BigD]

Well, thought I did it right, but apparently not.  When I set the camshaft timing, I noticed that the IP sprocket was not able to line up with hole for the locking pin and I couldn't insert it.  Didn't mess with it and now the car won't start.  Guess I'll have to go back and look again.  Can I just TDC the crank and cam and then just move the IP sprocket into place and lock it there?

Vince, was able to link to the article but missing pictures.


thanks again, all.  Going back in tomorrow.