I changed the timing belts on both my cars last weekend. I have all the tools, Vagcom, etc. The 2003 went perfectly, the car positively purrs at this point. It had a slight valve rattle at acceleration before that has disappeared now.
The 2002 was acquired this summer, supposedly with the TB already changed.
It had an old style INA tensioner with no indicator mark, there's a local guy that likes to use these tensioners.
It ran well despite still being on the old rollers and having the crank one tooth after TDC when it was locked down.
I changed the cam because it had some pitting on the external surfaces of the lobe. the lifters has some concentric circles that could not be felt with a fingernail. I used assembly lube on the cam, engine oil on the lifters and allowed an hour bleed down. I rolled the crank back 90 degrees to install the cam and moved it to TDC after.
I tightened the tensioner, tightened the cam sprocket, forgot to tension the three pump bolts. While running it through by hand I noticed after one turn that the pump sprocket was moving through the oval adjustment range. I locked everything down again, tensioned everything again and ran it through twice.
I then set it TDC, all was well.
Upon starting it up(it fired up immediately) I found it rattled considerably but I let it run to temper the cam and lifters. I then set the fine static timing with the Vagcom.
I drove it for a few days but found it rattled more than my 2003, especially on acceleration, so I used a dial indicator through the glow plug hole to find TDC. It turns out it's about 1/2 tooth after the indicated TDC on the flywheel.
A compression test gives 500-510psi on all 4 cylinders on a warm engine.
I think injector #2 is noisy and the balance on field 13 says +.68 for that cylinder while the others are -.10 to -.20
I raised the IQ from 2.4 to 3 and it rattled less but was not as much fun to drive.
Do I set it to the original TDC and just let it rattle because new lifters just do that?
Set it to the TDC found with the dial indicator?
Change the nozzles?
I'd like it as perfect as the 2003.
The rattle sounds like a TDI when it's driven cold and accelerating
Any ideas?
Thanks in advance for your help.
PS The new lifters already have small faint concentric circles that are light grey/brown in colour where the lobe contacts them. No cracking or crazing noticed. No indentation noticeable with a fingernail. The cam lobes look perfect.
The 2002 was acquired this summer, supposedly with the TB already changed.
It had an old style INA tensioner with no indicator mark, there's a local guy that likes to use these tensioners.
It ran well despite still being on the old rollers and having the crank one tooth after TDC when it was locked down.
I changed the cam because it had some pitting on the external surfaces of the lobe. the lifters has some concentric circles that could not be felt with a fingernail. I used assembly lube on the cam, engine oil on the lifters and allowed an hour bleed down. I rolled the crank back 90 degrees to install the cam and moved it to TDC after.
I tightened the tensioner, tightened the cam sprocket, forgot to tension the three pump bolts. While running it through by hand I noticed after one turn that the pump sprocket was moving through the oval adjustment range. I locked everything down again, tensioned everything again and ran it through twice.
I then set it TDC, all was well.
Upon starting it up(it fired up immediately) I found it rattled considerably but I let it run to temper the cam and lifters. I then set the fine static timing with the Vagcom.
I drove it for a few days but found it rattled more than my 2003, especially on acceleration, so I used a dial indicator through the glow plug hole to find TDC. It turns out it's about 1/2 tooth after the indicated TDC on the flywheel.
A compression test gives 500-510psi on all 4 cylinders on a warm engine.
I think injector #2 is noisy and the balance on field 13 says +.68 for that cylinder while the others are -.10 to -.20
I raised the IQ from 2.4 to 3 and it rattled less but was not as much fun to drive.
Do I set it to the original TDC and just let it rattle because new lifters just do that?
Set it to the TDC found with the dial indicator?
Change the nozzles?
I'd like it as perfect as the 2003.
The rattle sounds like a TDI when it's driven cold and accelerating
Any ideas?
Thanks in advance for your help.
PS The new lifters already have small faint concentric circles that are light grey/brown in colour where the lobe contacts them. No cracking or crazing noticed. No indentation noticeable with a fingernail. The cam lobes look perfect.
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