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Discussion Starter #221
I removed the valve cover and 1 valve was destroyed. The others looked fine. Timing belt was tight appeared not to have jumped... I need to remove the head. I couldn't find a valve12MM TRIPLE SQUARE CYLINDER HEAD BOLT TOOL locally - autozone, etc. I ordered one online. Should be here Monday.
 

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Discussion Starter #225
I got head back form Frank in Missouri. Installing timing belt now. Frank sent me timing belt tensioner stud but no nut. I have the old nut. Is it OK to re-use or should I use a new nut. It appears to be 8 x 1.25 nut
 

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Discussion Starter #227
As long as its not galled. Send it.
I found a quote from Frank where he says torque the cam shaft pulley at 44 lbs. Does that sound right? I know the book says 33 but he said in the link that book is incorrect and after much testing 44 lbs should keep it from slipping. I think that is what happened to my head.
 

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Discussion Starter #229
I have not choice but to use the old nut or the 8x1.25 from autozone. Can't a nut anywhere. Hard to believe no one sells them.
 

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Discussion Starter #230
I was attempting to find TDC with a wood dowel about half the size of a straw, I stuck it down in the glow plug port but about an inch broke off. I couldn't retrieve it . Would you remove head? I'm better to be safe than sorry.
 

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One could get the plug hole straight up, fill jug with water, see if straw floats?
Hook small tube to air gun, stick it all the way in, try blowing straw out.

Ed in CO
 

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Discussion Starter #233
127236

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Installed timing belt. Before mounting head, make sure #1 piston was at TDC. After installing head, verified again with coat hanger. Installed cam lock, loosen cam sprocket, Pinned injector pump. Once belt installed torqued to 44lbs(Frank advised) Since I don't have a mark on the flywheel (I wish it did), again followed followed Frank directions and harmonic balancer align with notch. I rotated the engine several times. I cam locked the cam shaft and pinned the IP and verified harmonic balancer notched was aligned. Seems like I have more compression; engine does not seem to rotate as fast. I bled the lines. Tried start but seems like engine is not turning fast enough. I charge the battery(1 year old). If everything is right, should fire up immediately. Hmmmm
 

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Discussion Starter #235
After the head rebuild by Frank, my truck runs good. Great power and fuel mileage. Still turns 4 to 6 revolutions before starting. If I jump from other pickup starts a little quicker. I have some clear line I put on and I could see a few very small bubble. From the pump to the return line a lot of bubbles. Don't know if that is normal. Timing is a little advanced. I have an inline flow through fuel pump, turned it on but makes no difference starting. From the Vagcom, this what I see.
127551


127552


127554
 

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Discussion Starter #236
After taking the starter three times to the starter repair service guys, they finally found the issue. Starter had crack in the solenoid. They repaired the starter and now starts like it should. Where is the best place to purchase a vacuum pump for my TDI? Do they make one that will not leak. The one I have is just a little over a year old and started leaking. I replaced it with a seal kit and now I'm finding oil in vacuum line to the brake booster. I finding a lot of parts are cheap and I'd rather pay more for quality parts that will last. Any suggestions on where to buy a quality vacuum pump?
 

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Just reseal the stock vacuum pump. never seen a vac pump worn beyond limits. Make sure your getting the good re-seal kit made by RKX.
 

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Discussion Starter #238
Just reseal the stock vacuum pump. never seen a vac pump worn beyond limits. Make sure your getting the good re-seal kit made by RKX.
Before resealing it worked perfectly other than a leak. After resealing at idle i pull off press brake and hard pedal. I removed thanking i left something off. Dnt see much u can screw up. Compared to old pump and all looks fine. I put back together notice oil in vacuum line. Now I have breaks when pressed but hard petal on second press like I m losing vacuum
 

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Before resealing it worked perfectly other than a leak. After resealing at idle i pull off press brake and hard pedal. I removed thanking i left something off. Dnt see much u can screw up. Compared to old pump and all looks fine. I put back together notice oil in vacuum line. Now I have breaks when pressed but hard petal on second press like I m losing vacuum
Do you have a vac ball resevoir in the system? some swaps need one if your vac system volume is small.
 

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Discussion Starter #240
I don't but I do have the ball that came out of the 2002 VW. I just remove and re-terminated the lines. Much better If press one time, it stops as before but if I pump the breaks three times, by the third time pedal becomes hard. I will try the ball tomorrow. Just never noticed this before. The pump is only a couple of years old. I replaced the original because it had the old style spout which leaked.
 
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