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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old August 5th, 2018, 18:42   #1
Liter_o_Cola
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Join Date: Oct 2017
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TDI(s): 01 ALH Golf
Fuel Economy: 44’s
Default 11mm injection pump trouble

Installing an 11mm pump. The problem Iím having is from TDC, I can only turn the crank about 1/2 a turn to verify everything is timed correctly before starting. The car was healthy before I started the install and now Iím scared to start it. Iíve removed the glow plugs to eliminate the possibility of a compression issue. Checked the TDC in the cam and flywheel, both being perfect, the IP is also good, but not a contributing factor. Any ideas at this point would be greatly appreciated as Iíve exhausted all resources trying to solve the issue. Iíll even throw a $50 bounty on whoever can show me the way to alleviate the issue!! I need to get it running by tomorrow!
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Old August 6th, 2018, 18:35   #2
[486]
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Bit late I suppose, but I'd bet on the belt having skipped some teeth on the cam sprocket, a valve hitting a piston making for the clunk while trying to bar the engine over. Where in MN are you? I'd stop by and help out if you're somewhat near by.
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Old August 7th, 2018, 22:20   #3
Liter_o_Cola
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I’m north of the cities about 2 hours. Ended up taking it in to a shop, there was no timing mark on the flywheel... so they figured it out. Got everything lined up and she’s running now. Unfortunately I’m away for 2 weeks so I’ll be wondering what the 11mm brought to the table in the meantime. Appreciate the offer though!!
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Old August 8th, 2018, 07:22   #4
[486]
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Oh okay, I'm pretty regularly in the east bethel area, so not quite that far out.
You're north of brainerd or hinckley?

Lots of aftermarket flywheels don't have a timing mark, or one in the wrong location entirely, pretty easy to add one though, just need a piston stop and a center punch. Clunk it one way, make a mark, pull the stop out, move it to the other side of TDC, clunk it the other way, make another mark, pull the stop and then split the difference.
I use a few leaves of a feeler gauge through an intake port to hold a valve open for the piston stop. Not many other options on a diesel.
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Old August 8th, 2018, 16:56   #5
Yourbuddysatin
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I had a vr6 years ago and the TDC mark on the crank pulley was wrong and we had to static time it thru the spark plug hole. Might be able to do it thru the glow plug hole? Then put a mark on the flywheel?
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Old August 10th, 2018, 10:57   #6
dieseleux
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Just in case, you have TDC mark on accessory pulley...




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Old August 10th, 2018, 18:01   #7
Yourbuddysatin
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Quote:
Originally Posted by dieseleux View Post
Just in case, you have TDC mark on accessory pulley...




Dieseleux

Mine doesnít but maybe thatís because itís a 99.5....
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Old August 10th, 2018, 21:08   #8
[486]
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Quote:
Originally Posted by dieseleux View Post
Just in case, you have TDC mark on accessory pulley...
nowhere near accurate enough for a Tbelt service
unless you're just flopping a new one on and hoping for the best, which I do to my own junk when I can, but a lot of the time that just can't be done, like when the cam pulley's been off.
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