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#15
by
libbydiesel
on 09 Jun, 2021 18:37
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Dial indicator works. I've also used a small clear tube from a glow plug hole to a container of water to find TDC and that works accurately also. I'm not sure which I prefer.
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#16
by
Zeitgeist
on 13 Jun, 2021 15:55
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I've tried the stick and dial indicator in both the injector and glow hole, but I can't get an accurate enough measurement due to it moving laterally or binding in the holes. I'll try the hose and water trick next. I can't find any TDC marks on the flywheel. I don't know how they timed either the AAZ or the AHU.
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#17
by
libbydiesel
on 13 Jun, 2021 18:45
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The stock diesel vanagon TDC mark is actually on the pressure plate. It is a V-notch between two small humps.
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#18
by
libbydiesel
on 13 Jun, 2021 18:46
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The hose/water method works great for finding TDC, though. I grease around the hose at the glow plug to make sure it isn't leaking. I've done it several times now and it has proven to be accurate. I like to go each direction to TDC also to double-check.
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#19
by
Zeitgeist
on 13 Jun, 2021 22:25
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The stock diesel vanagon TDC mark is actually on the pressure plate. It is a V-notch between two small humps.
The AAZ had a red South Bend pressure plate with no vee. I'm also not familiar with the type of flywheel they used, as it's 280mm and not 215mm like the NA diesels. Upon closer the inspection, the ring gear appears to have a yellow paint mark on one of the teeth. The engine is still on my stand, so I can't yet tell if it corresponds with TDC. The AAZ was swapped in the Netherlands, so who knows what kind of parts they used throughout. The fuel filter they used was for a Polo and some Seat model, and of course was not available over here.
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#20
by
srgtlord
on 15 Jun, 2021 12:43
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#21
by
Zeitgeist
on 15 Jun, 2021 18:09
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That little yellow paint mark on one of the ring gear teeth turned out to be TDC. It appears that a Mk3 flywheel was chucked into a lathe and turned down to fit into the diesel bellhousing. They took a lot of meat off, and it's considerably lighter.
I'll have to research a Mk4 or Mk5 manual, but are the DMFs intended to be installed as a complete unit, as in just torqued onto the crank through the already bolted on pressure plate?
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#22
by
libbydiesel
on 15 Jun, 2021 19:07
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Yes, the DMF can be installed as an assembled unit. Nifty feature, IMO.
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#23
by
Zeitgeist
on 06 Jul, 2021 14:36
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Is there supposed to be some kind of spacer between the DMF and crank hub? I'm getting serious interference that locks up the crank, and I haven't even torqued it down yet. I may need to delete the splash guard in order to free up the space.
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#24
by
libbydiesel
on 07 Jul, 2021 14:17
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The DMF does not require any sort of spacer. However, the stock diesel vanagon intermediate plate will not fit without being significantly modified. There is a totally flat version offered by some vendors.
Here's the 1-part version:
https://www.vwbulliparts.de/vw-t3-abdeckblech-zum-schwungrad.htmlHere's a 2-part version that makes oil pan removal easier when engine/trans are in place:
https://www.brickwerks.co.uk/t3-parts/engine-conversion-parts/1-9d-td-tdi/clutch/flywheel-cover-plates-t3-228mm-clutch.html I have made one before by tracing the bell housing and cutting from sheet metal using a metal cutting blade in a hand jigsaw for that 'high end ghetto' finished product. I have also seen where someone cut the offending material off the stock diesel-vanagon plate. If taking that route, it would be possible to weld in a flat piece in the area that was removed. I am not sure if the intermediate plate mounting bolts interfere with the DMF.
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#25
by
Zeitgeist
on 08 Jul, 2021 00:46
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Ok thanks. I ended up using my cordless grinder to cut the raised section out of the plate, while still leaving the three tabs to attach to the main seal carrier. This left the bottom open, but this bell housing has at least three large openings due to its being from a 1.6TD Syncro, so there's really no sealing this thing up tight. I think this will work. It's absurd how much work I've had to accomplish at the rear of this engine. I still can't fathom why they didn't put any TDC marks on the front pulley area. I've had to install and remove the DMF and bellhousing about five times during this process. It's currently hanging from my cherry picker. This is all work I hadn't factored in to my install time estimate and it still boggles my mind.
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#26
by
libbydiesel
on 08 Jul, 2021 20:32
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Sorry to hear of the difficulty. When I have installed the DMF, I have needed to pull the bell housing of the trans and bolt it on/off the engine a few times to get the clearance right but have not needed to remove the DMF. I believe the mark on the flywheel is used rather than the pulley end because the flywheel is larger diameter and so will give a more accurate reference. The stock diesel vanagon starter can also pinch the flywheel if a small amount of material is not removed from the starter.
