Timing 1.1 (cambelt change)

Hi

I've got myself a MK1 1983 1.1 golf with a snapped cambelt.

I've taken off the head and at the moment it is being re-conditioned.

The only thing I'm unsure of is how to set the timing/belt tension when i come to put it all back together. I've changed cambelts on a 1.5 and gti before, but this looks different, ie the idler ect.

Any pointers would be great!!!

Setting the timing belt up on a small-block engine is much simpler than on the larger ones - there are only three pulleys to work with, and one of them (the water pump) is not timed.

There is a good description (with useful photos) in Haynes OWM726 (the one that covers 1.1 & 1.3 cars), but basically, you set the crank pulley mark to TDC (of the two indicator marks on the block-plate, it's the one nearest the front of the car - the rear one is 6 degrees before TDC, and is used for setting the ignition timing, rather than the valve timing).
For the Cam pulley, you set the stamped dot on one of the Cam pulley teeth against the little metal plate that is bolted to the head, below the cam pulley, at about "6-o'clock".

All you do then is insert a screwdriver into the slot on the (loose) water pump, and rotate it towards the rear of the car, to tension the cambelt correctly, and then tighten the water pump bolts.
Correct tension is to be able to (just) turn the belt 90 degrees in the middle of the longest run between two of the pulleys.

PS: If you aren't sure about whether you've done this correctly, use a 19mm socket to turn the crank pulley two full rotations to ensure that even if the timing is wrong enough that the engine won't start, at least you know that you can try the key with fear of engine damage from valves hitting pistons - sounds a bit cautious, but the result of getting it wrong are very expensive  8O

Thanks for the top info and advice Type17.
 
I've just ordered the haynes manual, but it won't be here till after the weekend, and i was hoping to get it running by then. No patience!!

Thanks again

Stevo

Found this thread and it looked the most relevant to what I'm doing - basically I'm changing a water pump and cam-belt on my mates 1.1 Polo (1987 I think it is).

Anyway today I got all the bolts on the water pump undone except the one towards the front of the engine, which was completely inaccessible with the tools I had - has anyone else come across this problem? If so what tools would you recommend?

Also, in the process, I accidentally dropped the socket I was using into the bottom of the cam-belt guard thingy - does anyone know the best way of getting it out again? I tried loosening the pulley that drives the alternator so I could take the guard off, but the pulley was stuck on like a good-un…

Any help would be very much appreciated!

Cheers

Rich

I was talking about the big-block engine bits the other day, at http://www.vwgolfmk1.o…e=viewtopic&p=43981#43981, and the following part also applies to removing the lower cover:

"…ensure the engine is at TDC at the crank AND cam - crank goes around twice for every one rotation of cam & intermediate shaft, so it's possible to only check the crank and have the cam 180 degrees out

remove the v-belt pulley wheel at the crank (4 allen bolts, 6mm, likely to be rusty, etc, so clean out the hex-hole well, to give your key the best chance to seat itself properly, and open the bolts with a sharp jerk, rather than just pulling hard, which will round out these bolts)

then you can remove the lower plastic cam-belt cover (last bolt is hidden by above pulley)

You then remove the cam-belt itself (ensure the engine is still at TDC at the crank AND cam)"

Hope this is helpful - ask more questions if required…

You'll probably need a small (1/4-inch drive) 10mm socket and an extension to get to the last water-pump bolt. If you own a VW of any sort, these will be very useful items, so feel free to invest in them.

Thanks for the info and tips Steve  :wink:

I will have another crack this weekend and see if I can finish the job… Expect a couple more questions next Sunday!

Thanks

Rich

Those four hex head bolts - absolute swine to get out.  (Ask dubgrrl!!)

It is VITAL that they are properly retourqued - had one work loose on a 16v - just one bolt slightly loose and it lunched the engine is they are fundamental to the design.  The chances of you getting them off with the engine in the bay are minimal.  Expect them to be tigtened in excess of 200 ft/lb - they aren't coming off!!

I'd be more inclined to attemt to reach the dropped tool with something and push/grab it out.  Well acutally I woulnd't have dropped the tool down there in the first place.

You should also find that with the correct tool, all the bolts that hold the water pump in place can be remove easily by a fairly competant home mechanic.

You may also find that the water pump may move without loosening the 3rd one.  Always change the ruber O-ring on the waterpump as these NEVER reseal properly again (and water leaking inside your timing belt cover is certainly NOT desirable).

I've just ordered the haynes manual, but it won't be here till after the weekend, and i was hoping to get it running by then. No patience!!

If you have no patience - DON'T BE AN ENGINE BUILDER!!  The key to success is taking your time, be very methodical, don't rush, don't work to deadlines, just make sure you do every job thoroughly and properly - otherwise, what is the point?

Steve_Matthews said

 Well acutally I woulnd't have dropped the tool down there in the first place.

I guess you learn the hard way when you start out!

Cheers for the advice - I'm borrowing a friend's magnet-on-a-stick type thing and I'll have another go next weekend. No chance of me lifting the engine out at the mo as I don't have a crane…

I guess you learn the hard way when you start out!

I guess some people do.

Steve_Matthews said

I guess some people do.

Harsh! I can't believe that you've never dropped anything, anytime, anywhere, ever!  :roll:

I've dropped loads of stuff but never a tool from outa my hand into timing gear!

I dropped some of the frosting off my caramel filled donut last night when I nearly drove into an area of outstanding natural beauty 'coz I was enjoying the donut so much I forgot to look outa the windscreen.