Diesel Jetta (vege oil)

[Golf Loon]

We will have to take the camshaft out to machine the head. Surely?

[hiho]

head

You can machine the head with the camshaft installed, if you want to machine the heads off some valves...
Edison, if you loosen the bolt on the end of the camshaft and hit the toothed pulley with a mallet it will come off. There is no woodruf key or splines to locate the toothed pulley with respect to the camshaft. It is a smooth taper. Hence the position of the toothed pulley means diddly squat once the pulley has been removed from the camshaft (or if the old belt is replacedwith a new one). Also, to refit the belt, it is much easier to do when the the toothed pulley is removed from the camshaft as this allows for some extra slack in the belt and also for the belt to be positioned accurately on the injector pump and camshaft (before you tighten the cam pulley bolt).
When i did the roadside injector pump replacement i also reset the cam timing by removing the camshaft toothed pulley. It is easy to do and also is the easiest way to reinstate the timing belt.
I didnt have the camshaft locking plate, instead i eyeballed the slot to the machined cam cover surface. I would prefer to have the locking plate though as it provides a positive location to the camshaft when re-torquing the cam pulley bolt.
I hope that this contribution is not confusing
Matt

[Edison]

You can machine the head with the camshaft installed, if you want to machine the heads off some valves...

I think I can clean up the old gasket by hand, or at least try to first off, because I'm trying to keep things simple. No machining. If it's not (just) the gasket, it'll be so serious as I'll pull out the engine and maybe put in another... [Also the Electric car display is on this SUNDAY at rouse hill in sydney, so maybe I'll get too many ideas if it's more than the gasket]

Edison, if you loosen the bolt on the end of the camshaft and hit the toothed pulley with a mallet it will come off. There is no woodruf key or splines to locate the toothed pulley with respect to the camshaft. It is a smooth taper. Hence the position of the toothed pulley means diddly squat once the pulley has been removed from the camshaft (or if the old belt is replacedwith a new one).

Ahh!!!! now comprehension is dawning, thats what I didn't understand before...

I would prefer to have the locking plate though as it provides a positive location to the camshaft..

That's a part I don't get, I thought the locking plate jams between the top of the engine and the uppermost gear (cam). If the camshaft gear is removed, where is the locking plate and how is it working ?

[brackie]

Clarifying

The locking plate locks the camshaft (only).
With the crank at TDC and the camshaft locked the valve timing is locked.
The sprocket has no keyway so if you loosen it with the camshaft and crankshaft locked then it can be rotated like a windmill and it will make absolutely no difference to the valve timing.
If the injection pump is also locked then the camshaft sprocket can be loosened and this will allow proper tensioning of the belt.
Again.. I would advise checking the pump timing when the job is complete and more importantly tighten in the camshaft sproket bolt well beyond the specified torque.

[hiho]

Locking plate

the locking plate is jammed in the slot in the other end of the camshaft and locks the camshaft into the position of TDC.

[Golf Loon]

So if we take the rocker cover off and jam a piece of meatal in the other end, it will act as a locking plate.

Can we just mark the cam and put it back in the same place?

[brackie]

Yes

If you're removing the cam it can be replaced with the crank @ TDC if you make sure the #1 cylinder valves are fully closed. In this position the slot at the rear of the camshaft will be lined up with the rear of the cylinder head. It's still best to use a metal tab to lock it as that way you know it's exactly right.

Be very careful if you intend skimming the head. I personally wouldn't recommend it as the tolerances are very tight and it means that you will have to measure up the piston head protrusion and buy the correct thickness head gasket to suit. The diesel head is pretty robust and unless it's been overheated generally will not warp. Check it with a straight edge and feeler gauges if unsure.

[syncro]

Edison,
I have an Autobooks Golf workshop manual for sale (Golf 75-83) that has diesel information. Book is like new. $20 phone 9774 3298. I am at Picnic Point.



Apparently the pump has to be locked.

[Edison]

the locking plate is jammed in the slot in the other end of the camshaft and locks the camshaft into the position of TDC.

Ah!!!! now were talking!!! this is the first mention of the cams other end...!

Again.. I would advise checking the pump timing when the job is complete

Whats involved?

skimming the head. I personally wouldn't recommend it

I'll be cleaning it up by hand, I still need to get the gasket, and I want to put in a 4 notch, (it has a 3 at the moment) as I think it will reduced the compression and allow for wacky fuels to be used (you never know what you'll find when your collecting secondhand oil) with lessened risk of damage at the cost of poor(er) economy... what would you think?
Ta, syncro I've got two books at the moment, I'll keep it in mind...

[smithy010]

Doesn't one of those books show you how to lock the camshaft?

Would've saved us a lot of words!

[syncro]

Doesn't one of those books show you how to lock the camshaft?

Would've saved us a lot of words!

and how to lock the pump

[smithy010]

and how to lock the pump

Syncro, i think we covered how to lock the pump earlier in this thread.

I'll have to work on my description skills.

[Edison]

Possibly, there might have been something useable in the manual, but If we disccuss it here it's even faster and better for people who have no manual or people too lazy to turn those heavy heavy pages and risk paper cuts, and I'm going to take pics of the whole operation and post em up in the manuals section, so we can all see it, still, or we can all hold our tounge and log off 8-)
but not as much fun !

[Golf Loon]

Lets get the damn head off and end this speculation. Does anyone have a pic with dimensions of the damn locking tool and I`ll make one.

I reckon you are dreaming if you think the head is not warped or cracked. Remember, I have push started you car Edison and have seen the smoke out the back when it starts. Its a lot, even by Diesel standards.

Call me and we`ll arrange a time to rip the head off.

I reckon Syncros Diesel Specific book would be pretty helpfull too And he lives near you.

[syncro]

Here's the pump lock Matt.


I can't see anything about a cam lock.

I'll photocopy the relevant pages if you like.
Phill