basic timing how to?

[timmmy]

iv never had a diesel car,i have rebuilt loads a gti engines,i have a 1991 passat 1.6td
the engine was burning loads of oil so iv got another engine im gonna put in but i was planning on rebuilding my old engine it needs a rebore,all this i can do myself rebuild the bottom end etc.
but i dont understand how to time it as it doesnt have the tdc mark on the fly wheel and no key way in the cam shaft,i understand from reading this forum its timing is very important,can any body give me a basic guide to re timing the whole engine,and do i need any special timing tools any help would be great as i cant find any timing marks,thanks

[Northboundtrain]

Get the Bentley manual and the timing tool (dial indicator).  Your flywheel must have a mark or else it isn't the right one for the engine.

[Josh]

I've seen a good how-to on this that doesn't require using the dial indicator; but I looked and I think it's gone now (older than the 21 months or so of archived content).  You might find more help inquiring about this technique over at the www.vwdieselparts.com website's forum section.  

That's where I recall seeing it, and by a fellow who was very economically-minded, who set his pump for maximum fuel efficiency this way, by hand.  

 -Josh

[chrissev]

iv never had a diesel car,i have rebuilt loads a gti engines,i have a 1991 passat 1.6td
the engine was burning loads of oil so iv got another engine im gonna put in but i was planning on rebuilding my old engine it needs a rebore,all this i can do myself rebuild the bottom end etc.
but i dont understand how to time it as it doesnt have the tdc mark on the fly wheel and no key way in the cam shaft,i understand from reading this forum its timing is very important,can any body give me a basic guide to re timing the whole engine,and do i need any special timing tools any help would be great as i cant find any timing marks,thanks

You don't need to worry about the camshaft keyway for timing a 1.6TD.  To make sure that you haven't got the flywheel 180 degrees off mark, look for the little "0" beside the timing mark on the flywheel.  That way you can avoid having to take off the valve cover to line up the slot on the camshaft.  Timing the engine involves inserting a dial gauge into the injection pump and turning the engine backwards.  If you don't yet have the dial gauge I won't bother explaining the procedure to you.  You also need a special machined tool to hold the dial gauge steady while it is in the pump.  Get the tools and then come back and I'll explain how to use them.  The procedure is quite simple and is much easier than timing a gas engine car (and you do it with the engine turned off, not running).

[Otis2]

There's a very nice explanation, with photos, up at this web page:

http://www.cs.rochester.edu/u/jag/vw/engine/fi/timing.html