Many people wonder how to adjust both their camshaft and ignition timing.
Its very easy. Just say..... Thanks Black_cabbie and here is 5 bux for you!
Suppose everything is messed up or you are rebuilting your engine so I will start from scratch.
The Camshaft pulley has 2 important marks on it. A little notch on the engine side and a OT mark on the other side.
The flywheel. it has 2 marks. One notch showing the 6 degrees BTDC (Before Top Dead Center) and a little dot showing the TDC.
The dizzy. It has a notch.
Removing the spark plugs (if they are not out already) helps a lot.
Turn the engine BY HAND until you get this mark in the flywheel.
The little 0 mark in the center of the Hole in the gearbox. Thats the TDC mark. It means the No1 piston is in TDC position and both inlet and outlet valves are closed. maximum compression in the chamber.
That means that the spark plug is supposed to fire when the piston is at that point.
You might also have this type of flywheel.... it has only the 6 degrees BTDC mark.
If you are not sure about the flywheel, insert a long screwdriver in No1 cylinder through the spark plug hole and check while slowly turning the engine if the scredriver is moving. That will give you an idea if the piston is at TDC.
Go to the dizzy and check if it points to the little notch. If it doesn't you have to loosen the belt, get it off the camshaft pulley and turn the rotor by hand until it points to the notch. Put the belt back and make sure the rotor doesn't move.
Now check the camshaft pulley marks.
If you have a late Digifant engine you have a plastic cover which doesn't allow you to see any marks on one side of the pulley.
So you have the OT mark which is supposed to allign with the mark on the plastic cover. This mark is in the top center of the plastic cover. There is also a little arrow pointing down. The mark on the pulley should be under this arrow. If its not you have to loose the belt again and turn the camshaft until the marks allign. Make sure you don't move the dizzy rotor! The angle is a bit funny.... I know. Its supposed to be right under the arrow.
If you have an older CIS engine, you probably have the metal belt cover which exposed both sides of the crank pulley. You should be able to see this mark (Its a notch just like the previous photo, don't worry, the photo is borrowed) at that exact point.
Thats another shot of the mark. It is supposed to be level with the belt cover and the valve cover (under the holdown bars).
Tight the belt tensioner according to specs and make sure the belt is not too tight. You should be able to twist by hand 90 degrees. No more, no less.
The cam timing is finished. You have adjusted everything to VW spec which is 0 advance for the camshaft.
For the ignition timing you need a timing light to fine tune it. If you don't have one you can do it by "feeling" the engine.
So, Suppose that everything is correct, all the marks are alligned and you have tuned the engine a couple of times BY HAND to see if anything interfears. Everything should be ok. Put the dizzy cap on and start the engine. Normally the engine should start immediately.
Take your timing light (if you have one) and point it into the gearbox hole where the flywheel is. If you have a digifant motor, unplug the blue sensor (CTS sensor) and rev the engine 3 times over 3k to clear the ECU memory. Have someone hold the engine at 2250 rpm and observe the mark in the hole as the engine turns and the light flashes. The strobo light will flash only when No1 spark plug is fired which is when the piston it at the Top Dead Center, meaning the little notch on the flywheel should appear still.
For CIS timing is at idle speed (850 rpms). Make sure that all the accesories are switched off.
If it doesn't appear, loose the 13mm nut on the dizzy and slowly turn the whole dizzy while still keeping the revs at 2250. As you turn it you will probably hear the engine sound change. You will also "feel" the engine running rough or smooth. Normally as you get closer to the notch the engine should feel smoother, with no missfires and with higher more clean rpm. Turn the dizzy until you get the little notch in the center of the hole. Thats the 6 Degrees BTDC timing everybody has been talking about and you read it in all the manuals. Your engine is supposed to produce its peak power (if its standard).
Once you are happy with the timing, tight the 13mm nut on the dizzy again and check one more. if everything is still ok, plug the CTS sensor back and rev it 3 times again over 3K. Let it idle and observe. Chances are your idle might need some adjusting to get it to arround 850/900 rpm.
Thats it! You did it! You can now brag to your friends that you don't need a specialist to do it!
Modified by Black_cabbie at 8:11 AM 5-9-2005