HELP!

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

Hi, I did my TB change and Bert didn't seem to be running as well as before. So I went back in to check is sure enough the exh. timing was off or so I thought. Will to make a long story short when I try to rotate the engine it hangs up. I think my main problem is finding that 90 deg pin hole on the fly wheel. How many holes will the 6mm hex wrench fit into and how far in does it go when you are in the hole.

What happens if you take the TB off and line up the exh and intake pins then rotate the engine to the 90 deg pin hole? Any help would be greatly appreciated.

flman · **Posted:** Sun Feb 02, 2014 6:07 pm

I would think, if you pull off the belt and rotate the sprockets to a point of no cam resistance it should clear the pistons, but wait until this is confirmed by others. You could then find the mark on the crankshaft front of the engine and set in to 3 oclock, then you will be in a close spot to lock the engine. At that position all cylinders are below TDC. You can then turn the sprockets and put the pins back in.

Hopefully you did not break any rockers.

jeepdan · **Posted:** Sun Feb 02, 2014 6:45 pm

Guess, maybe you didn't rotate the engine by hand two revolutions and then recheck the timing before finishing the reassembly?
Don't run the engine anymore at this point.
If it were me, I would remove the valve/intake cover and check the rockers for damage.
Rotating the crank to 90 degrees ATD would be easy with the cover and cams off.
Having the timing mark/groove on the crank snout pointing 3 oclock while looking at it from front, then insert the allen wrench if you want.
Alot of extra work, but the rockers might be getting to the point of changing anyway.

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

Where is the mark on the crank shaft? I have not ran the engine and yes I was rotating the engine to check if the timing was correct when I felt a hard spot and stopped trying to force the engine around.

I'm trying to start over but can't rotate the engine to get back to where the cam pins can be put in.

So basically I want to set the timing from scratch.

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

What does the timing mark look like I've looked all over the balancer hub (crank snout) no marks :?:

It would be really easy if I could find the mark on the crank shaft :?:

jeepdan · **Posted:** Sun Feb 02, 2014 7:29 pm

Pictures are better than words, at least for me.
Scroll down until you find the pictures.
http://www.keepandshare.com/doc/6793025 ... -716k?da=y

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

I see a mark on the crank end photo that lines up this the bolt hole on the at 3:00. Is that it?

jeepdan · **Posted:** Sun Feb 02, 2014 7:47 pm

tedder wrote:

I see a mark on the crank end photo that lines up this the bolt hole on the at 3:00. Is that it?

Yes, that is the mark.

kjjet · **Posted:** Sun Feb 02, 2014 9:43 pm

See for the correct way to do it. viewtopic.php?f=5&t=78018

Good luck
KJJET

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

I completed the job about 9 tonight. I want to thank all that provided advice.

I ended up taking the TB off and letting the cams spring to no tension. I then rotated the engine so that the mark on the crank shaft was at 3:00 I found the fly wheel hole and put the 6mm hex in it. Rotated both cams and installed pins. loosened both cam bolts and installed the belt, tensioned it and tightened the cam bolts. Rotated the engine to check the timing and tension and put everything back. All done. :pepper:

flman · **Posted:** Mon Feb 03, 2014 7:37 am

tedder wrote:

I completed the job about 9 tonight. I want to thank all that provided advice.

I ended up taking the TB off and letting the cams spring to no tension. I then rotated the engine so that the mark on the crank shaft was at 3:00 I found the fly wheel hole and put the 6mm hex in it. Rotated both cams and installed pins. loosened both cam bolts and installed the belt, tensioned it and tightened the cam bolts. Rotated the engine to check the timing and tension and put everything back. All done. :pepper:

I am glad we were able to help you get it all back together and running. :JEEPIN:

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

Well, I thought all was well Bert ran well plenty of pickup. Pulled out of the parking lot at work heard a ticking sound accelerated and lost power and the engine sounded terrible like running on one cylinder. Obviously I have damaged something during the timing fiasco. Maybe what jeepdan said is correct I damaged the rockers? Any input?

The upside to this is I'm learning a lot :banghead:

kjjet · **Posted:** Mon Feb 03, 2014 10:08 pm

Yep...Need to pull the intake to inspect the rockers.

Good luck
KJJET

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

any procedures you recommend?

jeepdan · **Posted:** Mon Feb 03, 2014 11:06 pm

tedder wrote:

any procedures you recommend?

Sorry to hear the timing belt job might have turned bad.
Check this link out, pretty good.
I have been through it, it's quite a time consuming, back breaking job.
viewtopic.php?f=98&t=75479

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

Very interesting post on rocker replacement this and the factory manual and I think I can tackle it. It's the wife's Bert and she hasn't said anything but I think she is thinking "why didn't he just take it to the dealer?" :banghead:

flman · **Posted:** Tue Feb 04, 2014 8:17 am

tedder wrote:

Well, I thought all was well Bert ran well plenty of pickup. Pulled out of the parking lot at work heard a ticking sound accelerated and lost power and the engine sounded terrible like running on one cylinder. Obviously I have damaged something during the timing fiasco. Maybe what jeepdan said is correct I damaged the rockers? Any input?

The upside to this is I'm learning a lot :banghead:

darn, I thought all went well? How did you get it all the way to work and then have rocker problems? If you had any doubt about the rockers, you should have pulled the VC and checked them.

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

I got in too big a hurry so as the saying goes. Take the time it takes so it takes less time. :banghead:

tedder · **Joined:** Thu Sep 15, 2011 7:19 pm **Posts:** 137

I finished removing the intake/valve cover. The rockers are worn out at 97k :shock:

Hopefully all the metal as those rockers were wearing out was filtered out by my filter. I now understand the filter arguments. Here are some photos:

1. I found broken pieces of rockers in the top of the engine pulled all I could out with magnet. Will any pieces that I didn't get just go to the sump to be filtered out?

2. Can you tell if a valve is bent without removing the head? or Is a complete top end overhaul in store?

3. Should I re-torque my head if I don't need a full top end overhaul?

4. I have heard a lot about changing the glow plugs should I do it?

Any else you think I should so besides a complete overhaul?

Thanks,

Mike92104 · **Posted:** Sat Feb 08, 2014 9:52 pm

There's a lot of metal floating around. A the least I think I would pull the head and make sure none of the cylinders have been scored, and vacuum them out. Then have the head checked by a machine shop.

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