the madness never ends !! - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• the madness never ends !! by 2mAn on 25 Sep, 2007 10:48
• ok, a few weeks ago, i grew a pair of huevos and timed my freshly rebuilt 1.6 TD (turbo'd NA) for the first time ever. it took a few tries to get it right, but i managed to line up everything perfectly. cam plate was in, pump sprocket was locked in place, TDC mark on flywheel was perfect. car fired right with very little smoke. i was eccastic....
  
  well after a few weeks of driving, i noticed several things.
  -lots of vibrations in the cabin (im suspecting the pass side motor mount is bad, as ive replaced the rear tranny mount with a HD one and the front snubber mount with a poly one)
  - the car has started to smoke a lot more on cold starts and doesnt seem as "eager" to start as it was when i first timed it
  theres other things too, but not related to the motor, so ill leave those out
  
  so this weekend i decided i was going to re-check the timing since i was sure it was off. and sure enough, it was. im suspecting that the pump bolts rattled a lil loose and threw it out of spec. i had it set to 1.00 when i did it originally and it was at 1.4  when i checked it this weekend :shock:
  
  the bizarre part was that at TDC, with the cam plate in, the pump sprocket pin wasnt going in and the TDC mark on the flywheel was a tooth off. i went ahead and redid the timing back to 1.00, but it doesnt seem to have improved very much.
  
  i think im going to have to redo it one more time, but this time with everything locked in place as i did it the first time  :cry:
  
  there is some good news though: i hit 20psi pretty quickly and ive cranked the star wheel one rotation and its starting to get very very fun. if i could get this cold start issue resolved (and the other lil things) this car would be a blast. once its warm, there is no smoke, and it idles good
  
  heres the sexy *** for your viewing pleasure
  
  
  so im wondering, has this ever happened to anyone else?
  also, when i redo the timing, im going to have to take the timing belt off and im going to lock everything in place as they were the first time i did it, but im afriad in a few weeks i will have to do this again. is there anything i can do to prevent this from happening again?
  
  
  TIA this forum has been oodles of help  
• #1 by burn_your_money on 25 Sep, 2007 12:43
• I agree, it does sound like the cam pulley is slipping. If you do exactly what Andrew suggests you should be fine.
  You'll notice that it is much faster and easier to time now that you've done it once
• #2 by 2mAn on 25 Sep, 2007 13:05
• ok, two questions though
  #1 can you clarify the  "whapping" part?
  #2 any suggestions for an alternate sprocket holding method ?
  
  and yes it has gotten easier to time the motor, though i dont like the fact that i have to keep removing the upper radiator hose to do it. its the only way i can get the dial gauge in there
• #3 by burn_your_money on 25 Sep, 2007 13:08
• #1 I believe he means the bolt head on the cam pulley
  
  #2 get a friend to stick a wrench through one of the holes and push it towards the firewall as you tighten the bolt.
• #4 by 2mAn on 25 Sep, 2007 13:14
• Quote from: "burn_your_money"

  #1 I believe he means the bolt head on the cam pulley
  
  #2 get a friend to stick a wrench through one of the holes and push it towards the firewall as you tighten the bolt.

  
  
  maybe this pic will help me
  
  
  
  
  am i hitting it from the left? or from the top? ie am i whapping the bolt towards the transmission? or down towards the floor?
  
  sounds like whap from the left towards the tranny on the bolt, am i right?
• #5 by burn_your_money on 25 Sep, 2007 13:26
• Quote from: "2mAn"

  
  sounds like whap from the left towards the tranny on the bolt, am i right?

  
  
  That would make the most sense to me. That way of the pulley is not fully seated it should knock it into place.