Question #1)
How do I know where TDC is on my injection pump? When I was removing the timing chain sprocket from the front of the pump, I'm certain the pump got turned over, perhaps several times.

It's easy to find TDC on the camshaft (it's marked) and I'm reasonably certain I'll be able to find TDC on the crankshaft (heh). Any hints?


Question #2)
Does the 240D have a harmonic balancer? Is it the disc that's marked with the TDC offset markings that you can see directly under the TDC sensor? I didn't mark any of the pieces that came off the front of the crankshaft with their exact orientation at TDC. It just didn't occur to me at the time to do so.

Any advice on lining things up again at the front of the crankshaft?

Thanks.

- Nathan
'83 240D "Steiner"
'00 New Beetle TDI

Nathan:

Crank "pulley" is the harmonic balancer. It can be installed correctly or 180 degrees off! Make sure the pointer is aligned with the TDC mark when the #1 crankpin is up top. If you are using new pistons of different size, or have replaced rods, or had anything ground, please get the crank balanced before installation -- if it is significantly out of balance the engine will shake terribly. Balancer and flywheel are separately balanced on these engines, so only the crank needs balancing.

There is a mark on the splined shaft at the front of the IP, and a mark in the upper left corner (or lower right corner?). Line them up and the IP is at TDC for #1. If it is off, it will be 180 degrees out. You will be able to tell when you set injection timing (before the engine goes back in).

Location of injection timer (the centrifucal thing that the chain drives) isn't important. The splines for the IP aren't keyed.

Peter

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

Nathan,

psfred is correct that the IP can be 180 out, but that is if you are not looking at all the other marks.

To reassemble the engine; move the number one piston to near TDC. Carefully install the balancer, without pulleys installed, with the TDC marks on the balancer aligning with the pointer mounted on the front of the block. When mounting the balancer, DO NOT PUT PINS IN PLACE THEN DRAW IT TIGHT WITH THE BOLT!!!!!! If you do this, you can DESTROY the crankshaft. Take the two round pins out, place the balancer on the crankshaft aligning as described above, and with the pin slots in the balancer slightly counterclockwise from aligning with the slots in the crankshaft. This is because it will turn slightly while the bolt is drawing it on. Draw the balancer on with the bolt. If it does not line up, pull it with the balancer puller and try again. You may have to do this ten times to get it to line up properly so that you can place the two pins in place. If it takes you fifty times to get it lined up properly, do it. Crankshafts have been destroyed by just drawing it in place with the big bolt and putting it on the road.

Once the balancer is in place, turn the balancer to TDC, if the camshaft mark does not align with the cambearing stand mark, turn it one full turn to TDC. Once the engine is in this position, align the slot in the IP shaft spline, with the mark that you will find next to one of the three screws on the front of the IP. Carefully slide pump into place with the IP mark aligned with the block mark, this is at the front outer portion of the IP.

Once the pump is in place, fill the main filter with fuel and the primary filter with fuel, and maybe you'll need a hose pointed up with fuel in it. With your thumb and forefinger over the two barbed fittings at the top of the main filter housing, pump the handpump to build pressure in the system to do your start of delivery adjustment with drip tube in place. This is all if you are doing this with the engine on the stand instead of in chassis. The reason I did this on the stand was to ensure that I didn't have to end up removing the oil filter housing while engine was in chassis to retime the IP.

Hope this helps,