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Thread: 1.6 Diesel timing issues

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    Junior Member dahunter_2007 is just really nice dahunter_2007's Avatar
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    1.6 Diesel timing issues

    I just replaced the timing belt on my 81 1.6 diesel. When I checked to make sure all the marks were in line (after removing the old belt) the cam and IP were but the flywheel had no mark to be seen through the hole in the bellhousing.

    I assumed that the crank had moved so I turned it till the only mark I can find on my flywheel ( which looks like a 0 with a line above it) was allined with the pointer on the bellhousing and put the belt on. I checked once more to make sure they were all lined up and they were. I then turned the engine over to check for binding and there was definitely binding between the pistons and valves.

    So I took the cam out and held down a valve for the #1 cylinder until I could see the valve move up from the piston pushing on it and when it stopped moving up I stopped moving the crank. Looked at the flywheel and there is no mark. Is there any way my flywheel can be on wrong inturn making the TDC mark wrong?

    Any help would be greatly appreciated!

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    Re: 1.6 Diesel timing issues

    I have heard that there are pressure plates with the incorrect mark.

    But I would suggest that you do the following.

    Set the tranny at 0tdc, remove the valve cover.
    The flat of the cam rear should be equal to the valve body, and that the number one valves are pointing up, use a steel plate (I used a steel ruler from a stanley tri-square, to lock the cam, set the ip to the marks.

    Now I have had to turn the engine a bit, then the cam a bit then the engine a bit to get it to time. It is a pain but you have to do it to insure that you are in time. Once you lock everything down rotate the engine 2 or 3 times by hand to verify that no valve to piston grindage occur.

    (you do have he big plastic plug removed from the tranny?)
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    Senior Member amesghali has a brilliant future amesghali has a brilliant future amesghali's Avatar
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    Re: 1.6 Diesel timing issues

    Dude,

    My 81 Caddy was the same. I go to time it and after lining everything up on TDC, the flywheel had no mark to be seen through the hole. But I make no assumptions! The truck was running before - a bit rough, but running. So I'm not about to move the crank to a different position and risk damaging the valves. I just put a dab of white paint on the flywheel where hopefully it's at TDC.

    Oh and yes, with the timing belt in place I rotated the flywheel 360 looking for marks and did find what looked like a timing mark, but it was about 180 out of sync Obviously it was not the timing mark. I decided not to F with it and just timed it. It's running fine!


    UPDATED.....

    Today I lined up everything up TDC again and looked on the flywheel. Just above where I put the dab of white paint, i could see the bottom half of the "0". I angled my flashlight and voila! I see the whole "0" and above it the notch on the flywheel.

    So for other newbies to the Rabbit like myself, The "0" and the notch for TDC on the flywheel is up high and not easily visible through the transmission peep hole - especially if you have lost your peephole cover like mine.

    Click image for larger version

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    Last edited by amesghali; 01-04-2011 at 02:14 PM.

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    Senior Member DjDazer is just really nice DjDazer's Avatar
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    Re: 1.6 Diesel timing issues

    That yellow piece thats making it hard to see can be removed with plyer's.
    Flywheel TDC:

    Cylinder 1 Facing Up:

    Fuel Injection Pump:

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    Junior Member DirtNap is just really nice DirtNap's Avatar
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    Re: 1.6 Diesel timing issues

    amesghali please don't start down the road I am at now. This was the way my bunny was timed when I got it and it will run but give you nothing but trouble and there was mild contact when it was rotated. When I got my manual the picture you showed was the mark they want the crank at for pulling the engine. The actual TDC mark is further over to the firewall side as I think you stated i the latter post. Notice the difference between your pic and the one DjDazer posted you need to remove the plastic plug to see the alignment mark on the case.
    Click image for larger version

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  7. #6
    Senior Member DjDazer is just really nice DjDazer's Avatar
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    Re: 1.6 Diesel timing issues

    Also amesghali i bet you didnt set the timing right without removing the cap to the flywheel tdc. That mark on your pic isnt the 0 tdc mark

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