RE: crankshaft, intermediate shaft timing - SHAFTED- HELP!

["Aaron Ness" <aaron@makuta.com>]

If I'm not mistooken, timing belt installation is done with cyl. 1 on TDC
compression.  I would try putting it there (check the rotor to see if it's
at #1 and carefully put a screwdriver through the spark plug hole to find
TDC) and checking to see if the mark on the cam pulley is in the correct
place.  If it's not, I would suspect that the cam timing is off and keeping
it from starting.

The intermediate shaft doesn't really even need to be lined up (my brother's
A2 GTI wasn't when we did his timing belt).  The only problem I see is that
if it's not lined up at the end of the procedure, your timing will be off,
but I would reset that after replacing the belt anyway.  Of course, if the
intermediate shaft is way off, your distributor will have to be rotated
really far and I'm not sure if you would run into interference problems with
the block.

HTH!
Aaron
'84 Scirocco - Woo-hoo!
'70 Bug - hibernating
'87 Nissan truck - Soon to be for sale
'87 Jeep Cherokee 4.0

> -----Original Message-----
> From: owner-scirocco-l@scirocco.org
> [mailto:owner-scirocco-l@scirocco.org]On Behalf Of Victor Farren
> Sent: Wednesday, April 12, 2000 8:36 AM
> To: scirocco-l@scirocco.org
> Subject: crankshaft, intermediate shaft timing - SHAFTED- HELP!
>
>
> This isn't on a scirocco, but my brother's A1 Jetta w/ a  8v JH engine
> so I guess its kind of appropriate for the list.  Pretty long so
> please bear w/ me.
>
> We are having difficulty timing the crankshaft to the intermediate
> shaft after removing and replacing the timing belt and we can't get
> the car to start.  The following is what I know, according to
> Bentley:
>
> align the notch in the crankshaft pulley with the punch mark on the
> intermediate shaft sprocket.  Align the punch mark on the inside of
> the cam shaft sprocket with the top of the cylinder head (so, a hair
> below the valve cover).  This I can do, and have done in the past w/
> other JH engines, so I do know how to replace a timing belt and get
> the car started on a car with no AC or power steering.
>
> It appears that the Jetta had power steering or something b/c there
> are 2 pulleys on the crankshaft.  In act, the inner pulley is made up
> of two rings (for lack of a better word) seperated by spacers,
> followed by a genuine pulley on the outer edge of the crankshaft.  The
> inner pulley has no belts running on it, while the alternator, water
> pump belt runs on the outer pulley.
>
> PROBLEM:  Neither pulley on the crankshaft has a notch in it!!!  The
> only mark visible is on the outer pulley, and this has a large punch
> mark (more like a circular indentation about 2 cm diameter) on the
> actual face of the pulley, about 1-1.5 inches from the lip of the
> pulley.  I have never seen a pulley like this, and it makes it a real
> b*itch to try and line up w/ the punch mark on the intermediate shaft
>
> WHAT I DID (TAKE #1):  I marked a line on the outer edge of the outer
> crankshaft pulley in line w/ the 2cm diamter indentation.  I lined up
> this new mark w/ punch mark on the intermediate shaft and proceeded to
> put on the timing belt after aligning the camshaft w/ top of cylinder
> head (followed Bentley procedures).  I accounted for movement in the
> intermediate shaft and camshaft so in the end all the marks lined up.
> Turnd engine to where the timing mark on the flywheel was pointing at
> the arrow on the bell housing.  Looked at where the rotor was pointing
> and ran spark plug wire from that post on the distributor cap to the
> #1 cylinder.  Followed firing order of 1,3,4,2.
>
> Cranked engine and didn't start.  Loosened distributor and moved it
> around a little while brother cranked engine.  Nothing, no sound of it
> even trying to start.  Didn't seem liek I was getting spark to the
> correct cylinder.
>
> TAKE #2:  Did above procedure, but this time trying to align notch on
> intermediate shaft with the 2cm diameter indentation on crankshaft
> pulley.  Very hard to do b/c the mark is on the face of the pulley,
> and the center puch on the intermediate shaft pulley goes behind the
> crankshaft pulley when the marks line up.  Did the same thing w/ the
> flywheel, etc, with same results.
>
> WTF!  What am I doing wrong?  I have never seen a pulley set up on
> the crankshaft like this one.  This is really starting to get on my
> nerves b/c I have been trying to get this thing started for 2 nights
> now.
>
> Car has brand new spark plugs, cap and rotor as of last night.
>
> If you have read this far I thank you, and would love any input.
>
> Victor
>
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