update: Crank shaft woodruff key Q's

[treed2 at u.washington.edu (T. Reed)]

Drop a long dowel down the #1 spark plug hole and find TRUE tdc by turnin=
g
the engine by hand until the dowel's height is maximized.

Then check all your other marks. It sounds to me like your valve timing i=
s
off (and consequently your ignition timing since the dist is
driven off the exhaust cam.. that's why your dist cap is turned
all the way. I experienced this firsthand)

I had this problem (valve timing being off) and it was due to the keyway
in the crank being damaged. Any amount of damage to the keyway is
significant because it is such a small diameter sprocket. The same damage
to the key/keyway on the cam sprocket would be less noticable because the
cam sprocket turns twice for every crank sprocket revolution.

Just 0.5mm of play in the crank keyway is ~ equivalent to about 1 tooth
off on the timing belt. So 1mm of play is 2 teeth, etc. Anyone who's had
their timing belt off a tooth knows how huge of a difference this makes.

-Toby

On Mon, 20 Oct 2003, Julie Macfarlane wrote:

> I changed the crank/timing belt pulley with one in better condition. Th=
e old
> one at least half of the key was gone, and a small bit of damage to the
> keyway.
>
> When I time the engine I set the mark on the plastic cover with the mar=
k on
> the pulley (&the top of Cyl#1 with the top) it does line up correctly. =
Same
> for the fly wheel.
> I set the upper cam to the mark on the valve cover.
> The car will run but veryn poorly. The dist is set at the exteem edge o=
f the
> setting (all the way forward).
> Any less than this and it barely turns the engine, here it revs the eng=
ine a
> lot. The timing light shows both the top and the bottom timing marks ar=
e
> towards the rear of the engine. No adjusting of the dist will make it m=
ove
> forward to the correct marks.
>
> Any ideas guys?
>
> Julie's beginning to get pissed with this.
>
>
>
>
>
> Julie Macfarlane
> Menlo Park Research & Development
> Internet Application Developer
> www.menloparkrandd.com
> www.montgomeryweb.org
> Amsterdam NY
>
>
>
>
>
> >From: marc_scirocco Qu=E9bec <marc_scirocco@sympatico.ca>
> >Reply-To: <marc_scirocco@sympatico.ca>
> >To: "Julie Macfarlane" <juliemac57@hotmail.com>,<scirocco-l@scirocco.o=
rg>
> >Subject: RE: Crank shaft woodruff key Q's
> >Date: Mon, 20 Oct 2003 10:50:52 -0400
> >
> >Inspect the crankshaft end. It has to be perfect, or the key will brea=
k
> >again and again. If not, you need another crankshaft.
> >
> >Make sure you follow the proper procedure to tighten the bolt. What pa=
rt
> >number is your crankshaft sprocket?
> >
> >Cheers.
> >
> >Marc
> >'83 Scirocco
> >'88 Scirocco Slegato
> >
> >-----Message d'origine-----
> >De : scirocco-l-bounces@scirocco.org
> >[mailto:scirocco-l-bounces@scirocco.org]De la part de Julie Macfarlane
> >Envoy=E9 : lundi 20 octobre 2003 09:28
> >=C0 : scirocco-l@scirocco.org
> >Objet : Crank shaft woodruff key Q's
> >
> >
> >I have discovered the PITA of the cars. The crankshaft bolt came of
> >REASONABLY easy (took heat on the 12 point bolt), but the key on the
> >crank/timing belt pully was only about 3mm across instead of the full =
size
> >and the slot in the crank was damaged. It is "smeared" a bit, no metal=
 from
> >the key either, just rust.
> >Chris, this was a used part right?
> >
> >I took the part I needed from another 16v and it seems like new, no ru=
st or
> >damage to the key. Not bad for a worn out engine....
> >It took a bit of tapping with a BFH to settle it correctly and seems
> >secure.
> >The bolt was replaced by the 6 point bolt from the older engine.
> >
> >Q is, will this work for me or do I have a dud engine... I am hoping I=
 dont
> >have to pull the crank to replace it. If I do.. How much are they?
> >
> >Also how do I get the engine from turning while I try to tighten the b=
olt?
> >
> >Frustrated....
> >
> >
> >Julie Macfarlane
> >Menlo Park Research & Development
> >Internet Application Developer
> >www.menloparkrandd.com
> >www.montgomeryweb.org
> >Amsterdam NY
> >
> >_________________________________________________________________
> >Cheer a special someone with a fun Halloween eCard from American Greet=
ings!
> >Go to  http://www.msn.americangreetings.com/index_msn.pd?source=3Dmsne=
134
> >
> >
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