Mechanic advice needed - VW T4

[Christophski]

Hi guys

I was hoping someone on here would be able to help as the bloomin van forum is not seeming overly keen on passing on advice.

As many know I have a VW T4. Its a 1.9td ABL engine. I have just had the cambelt off to do a diesel pump rebuild. With this done I have been putting it back together and got the cambelt on using a tipex marking that was there and when lined up was in line with allowing the pin to be put int he fuel pump and the plate in the end of the cam. I have had a mate helping me on doing this as he is a mechanic. He has pointed out a few things to me that I would like to know answers for.

1) We cannot find the mark on the flywheel. Does anyone know where I should be looking for this? Or is it likely its had a flywheel replacement and this one does not have a tdc mark?

2) My friend thought there should be markings on the cambelt covers to line up with other markings on the pulleys. There was markings on an old vans covers I had but there doesnt seem to be any on this one. Should there be markings on this cover or not?

basically i want to check its all at TDC before I start it. I also am not sure how much i trust the tipex marking that was there in the first place even though when I did the cambelt the first time I used it and it seemed to have worked fine. My friend did however point out that it still coudl have been half a tooth out so really I should be checking it with the proper markings. So basically im after any guidance if anyone may have any for me

Thank you in advance for any help

[rj scotty]

Fly wheel mark is really hard to see

[Sleeper_Avant]

turn it over by hand, no resistance should be fine to crank over.

alternativly pull a heater plug from no.1 or 4 and check for TDC, then look for crank mark!

although it should just "pin up" without issues?

[Christophski]

It's been turned over a few rotations by hand ok and it still pins up.... Still can't see any marks on the flywheel though oddly. Heater plug? Glow plug?

[rj scotty]

yes

or you could take injector out

[Monkeymagic]

tdc will be on flywheel somewhere. cam timing is done with cam cover off and flat bar on none pulley side as Im fairly certain the cam pulley is a conical taper eg no woodruff key.
Pump fits in place with a 10 mm locking pin.

[Monkeymagic]

Sorry its an 8mm drill bit in through the window in the pulley into the hole in the back plate. Fine tuning can be done with the three bolts on the pulley to tweak it. easier than the 2.5 tdi by far.

[rj scotty]

with loads of tippex marks and vag com the tdi is not that bad but fine tunning the injection timing can take ages to get bang on.

The fly wheel mark is nearly impossible to see with out an inspection camera though amd I asume the 1.9 is just as bad

[Monkeymagic]

You cannot time the position of cam to injection pump with tip pex on these. Also they don't have an engine ecu so vcds won't work. Its a dial gauge to be certain although when they are right they sound right if you know what i mean

[Christophski]

Cheers guys. As said the 1.9's dont have an ecu so cant fine tune the timing like you can on the 2.5's.

My pump timing pin is a 6mm pin. The 7 & 8mm pins didnt fit, even previously when the pump was off and stripped down by a local diesel specialist who did the pump rebuild for me.

Seeing as its been cranked a fair few times by hand and each time the pin and plate have fitted back in and the tipex mark on the bottom pulley has lined back up again im gonna try doing it with the key later. I have since found out the 1.9 engines do not have markers on the cambelt covers like the 2.5's hence why I cant see them. (I know about the ones on the 2.5 as I used to have one)

So fingers crossed this evening or when I get back from my holiday next week I will get it going.

Cheers for all the advice and pointers guys. Sounds like me and my mate have done it right but just cant f ind the flywheel marking which sounds near on impossible to find by eye anyway lol!