Guy's,
I installed a new timing pulley on my buggy and at the same time I swapped out the vacuum dist. for a 009.
The old dist. was hard getting out and the 009 was equally as hard getting in. The "O' ring was new and stiff so I had to push pretty hard and wiggle it a lot.
When I rotated the dist to get the motor started the timing TDC had moved about 30 degrees to the left of where it is supposed to be.....
How could I have caused the dist drive gear to shift?  Is the drive gear that touchy?  Can I run it that way, will it cause a problem?  I have timed the motor by ear and I have it running good.
Is there a way to get the TDC back to where it should be without splitting the motor case????  For now should I find the TDC of number one cylinder and put a mark on the motor case and call it the new TDC and leave it that way until such time the motor is re-built???  Do I run the risk of the drive gear shifting while I'm driving down the road???
It took me a lot of time and work and figuring what actually happened.  I swapped out other distributors and rotated the rotor shaft figuring I had it wrong.  The bottom line is I really think I moved the dist drive gear???

Has anyone else done this or am I the only one??

Any thoughts, advice and suggestions would be greatly appreciated.

Jim B.  

This is a picture of where the distributor drive should be when the engien is at TDC on number 1 cylinder. Note the offset of the slot in the drive and how it points to the front stud on the fuel pump flange..


You can have the drive pop out and move if it sticks to the bottom of the distributor when you're pulling it out. Don't worry it won't move at all or change once it's back in. TDC on the engine pulley has not changed only where the rotor lines up. You can pull the drive out if you have the tool to pull it, it's about $25 from any VW shop. You may also be able to get in there with some heavy snap ring pliers and grab it.

You can run it the way it is without hurting anything, but, you should get a timing light on it to set your 009 to 28* total advance (at around 2500rpm)

brad

Brad,
WOW! I thought I was going to have to split the case to fix the problem.  Thanks I will make make a new TDC mark on the case and put a timing lite on the timing and make sure I have it set to no more than 28.

I was making a fix to my 34 PIC 3 / 009 dist. hesitation problem.  I found a link on the Meyers Max site it is  Aircooledtech.com  have you looked at it.  I soldered the hole in the throttle plate on my carb. and reinstalled it.  That fix my particular problem, my buggy seems to run great no stumble or hesitation at low RPM and I seem to be able to pull hills better without shifting.  I can also get it to idle better.  I haven't run it too much due to the timing issue as I explained in my post.
I will try to fish the drive gear out and set it as you showed in your photo.  If I can't do the job with a pair of snap ring pliers I will look for the proper tool at the VW shop..... Your pic doesn't show the little spring that in the center of the drive gear.  Will I loose it when I try to pull the gear up to reposition it?????   Should I try to grab the spring and take it out then put it back in, will it come out with a little pulling????? 

As usual you have come to the rescue.
By the way when are you going on vacation and picking up the new Buggy you posted about?  Will you tow it home or are you going to take a trailer along.  That sounds like a lot of miles if you are dragging a trailer, I know because I have done it....

Thanks again and I'll let you know how I make out.
   Jim B

Jim,

This is the best part of Brad's post: "You can run it the way it is without hurting anything."

Bring the #1 to TDC on the compression stroke (important...compression stroke) then install the distributor in so the rotor is pointing to the #1 cap wire spot. The just set the timing like Brad said.

Don't make it any harder than it has to be. You may have rotated the dizzy drive gear but its only purpose is to spin the dizzy. The motor could care less which hole in the cap has the number 1 plug wire in it as long as they are in the correct firing order and the rotor points to #1 when #1 is at TDC of the compression stroke.

We're leaving Labour Day Monday and will wind our way down to Utah. I'm hoping to take the old highway for a while south of Great Falls. The interstate is nice road, but I really want to get off it and enjoy the scenery for a change. Ya, it's a long way to drag a trailer, but my trailer is very light and I can't even really tell it's there behind my 4 cylinder Colorado. It'll be the last trip for me and this trailer after 20 years of service. I've made a deal to sell it and will be building a new one this winter. The biggest problem wiht this one is it's not spriung at all and was never set up for rear engine cars like a Beetle. The buggy isn't too bad, but my 57 is really hard to tow as too much weight is behind the axle on the trailer, so a new low deck, sprung trailer is in the design phase.

brad

Jeffrey,
I have read and re-read your note here and I can't quite understand all the you say.  This is what I have done.  I have installed the dist.  But when I start the motor and shine the timing lite on the pulley the TDC mark on the pulley is off the the left almost behind the fan belt so I no basis to adjust the timing (no mark).
I figure I should rotate the motor to TDC with #1 cylinder on it's compression stroke and the TDC pulley mark will be at the casesplit timing mark, but the rotor will be pointing some where else.  I should make a mark on the case where to rotor is now pointing and that mark will be what I use to adjust my timing...  Does this procedure sound correct. 

   Jim B.

Set your crank pulley to TDC of the compression stroke on #1. This remains constant and unchanged. The mark on the pulley has to line up with the case split Then turn your distributor to where ever you need to line up the rotor with the mark on the distributor body for the #1 plug wire. This should get you close enough to start it. Then rev the engine to at least 2300rpm and set your total advance to 28* BTDC.

brad

Brad and Jeffery,
You have know idea how much help and education you provide to us noviceses.  Experience is the best teacher and you guys give us enough guidance and step by step instructions to gain confidence to learn.

My distributor problem turned out to be three fold.  I had it installed wrong and was reading the timing wrong.  But in my defense the distributor I was trying to install was defective.
Brad and Jeffery , once I followed your directions I was able to realize I was installing the dist wrong and when that failed I realized the dist was defective ( the dist kept raising up and slipping out of the drive slots and continued to give me different timing readings)..  You gave me enough information and direction to figure out the solution.....  Had you lived next door I would have gone over, you might have fixed the problem and I would never really have learned how to get through it myself.  Thank you!!!  I hope this makes sense.
My buggy now runs pretty good and the timing is right and constant, I get the same readings every time I check it.  Does anyone want to buy an EPI 009 dist slightly used that won't stay in the "dist drive slot"???

Brad, by the way have a good vacation and enjoy your trip home with your new buggy behind.  If you are like me you will be anxious to get home and get started on the build....  be careful and have a nice vacation!?

And, again thanks for your help!
   Jim B. 

Yes Brad and Jeffrey I second that.  Jeffrey has been especially helpful for me and generous with advice.  I know this takes time and its really nice of you guys to help others.  Your generosity with your knowledge does not go unnoticed!!

More than glad to help out when I can, but thanks for the appreciation. We all had to learn from someone and I had some (and still have) some great people that help me out when I'm lost.

Jim, make sure you check your distributor hold down clamp. If it is holding the distributor tightly there is no way the distributor should pop up. Or, is it a case of the shaft was machined too small on the distributor?

brad

Yes..thank you for your appreciation. Its a great combination when advice works out. First, people have to be smart enough to ask. Second, people need to be willing to take the time to respond. And third, people need to appreciate the responses. When it all works out everyone wins.

And Jim, I agree with Brad. The dizzys can sometimes get stuck on the clamp by just a little bit. Its like 1/8" and often hard to see.