TDC...Which Is Most Important ???

Lindacars · #1 05-18-2004, 05:11 PM

Hello all you Guys,
I have a 71 stock VW bug with a 1600 daul port engine.
I am just now in the process of starting to work on my VW.
I was just getting ready to put in a new Bose 009 distributor with all new Pertonix Ingition kit that includes the
Pertronix Ignitor II and the Pertronix Flame Thrower II Coil.
I got this VW durning the winter and it was running but sluggish and
I have never driven it yet. I wanted to first put the new electronic Ingition kit in first but I just came accross a problem..............

I was just starting to put it at TDC so I can take the old distributor out BUT when I turn the crankshaft and put the rotor at #1 spark plug wire where the notch is on the distributor, then the notch that is on the crankcase is to the left about an inch away from the split in the crankcase...SO do you know what I should do???
This is my first time ever doing anything with a VW but I do have books BUT none of them mentions what to do if you come accross this with TDC and is it more important to have the rotor at #1 spark or the notch in the crankshaft ???
This is the first time in a long long time I have had a car with a carburetor and points and you know what I mean!!!
Also I just installed a new carburetor yesterday too.
Any HELP you can give me sure would be nice and maybe
I can get this VW on the road again.
Thanks...LINDA
in North Dakota

Doug Rodrigues · #2 05-19-2004, 10:28 AM

One inch isn't anything to worry about. The points will still open and close at the right time with the rotor pointing at the proper plug wire (assuming that you have the points properly set at .018 OR dwell angle set, if I remember correctly, at 45 to 50 degrees). You can twist the body of the distributor to line the rotor up with the notch, or pull the distributor up and move the rotor one notch in the direction you want it to be, and then push the distributor back down into position. No big deal. If you have a dwell meter, simply connect it to the distributor. With the cap off and ignition turned-on, crank the engine and adjust the dwell angle while the engine is cranking. That's the easiest way to set the points.

**See what Gunngee wrote below: I was wrong...the distributor can only go one way. I forgot that there isn't a gear at the end of the shaft, but an offset key/slot affair that can only go on one way.

boschmann · #3 05-19-2004, 03:54 PM

After installing the distributor w/ignition unit you will need to set the ignition timing anyway. The distributor will only go in one way, so as long as the distributor drive was put in correctly there won't be a problem (even if it wasn't put in correctly you can compensate for it). Just be sure you're on #1 TDC, not #3 TDC (check the valves if necessary) and when you put in the distributor rotate the housing so that the rotor (which won't turn) points to the notch in the distributor housing for #1. Then place the plug wires into the cap accordingly. You will then need to set the ignition timing either statically or with a timing light. From my experience with those electronic units I would start a 10 degrees BTDC and test drive. If it spark knocks under load retard it a little, if it is sluggish or hesitates on takeoff or shift to second gear advance it a little.

Lindacars · #4 05-20-2004, 06:46 PM

Hi, guys! It's Linda again and I'm really having a problem. Right now I am trying to put the new Bosch 009 into my distributor, and it won't go in! I have tried for two hours, but I cannot alaign it! Help! What should I do?!

Doug Rodrigues · #5 05-21-2004, 12:47 AM

Do you still have the original distributor from which you can check or compare the dimentions of the body and gear? How far can you push it in now?

Gunngee · #6 05-21-2004, 02:37 AM

Umm VW beetle distributors will only go in one way, there is no way to put it in 180 out or anything like that, there is no gear on the end it's just an offset keyway that will only allow it to go in one way!

Gunngee · #7 05-21-2004, 02:40 AM

Sorry not meaning to spam but I just had another thought. You said it was a new distributor, I am assuming there is a new seal on the distributor shaft as well. I had problems with mine whenit was new, it was very tight going in. I had to open the distributor clamp with a screw driver to get the seal past it. Just a thought.

Doug Rodrigues · #8 05-21-2004, 02:59 AM

Oh, Gunngee is correct. I haven't worked on a VW since 1975. I forgot that it has a key at the end that plugs into a slot. See what age does to one's mind? It all seems like a distant dream now.

Lindacars · #9 05-21-2004, 07:39 AM

Hi Guys it's Linda again.
I did spead the dist. clamp so it will fit the new 009.
But I just can't get the dist. to fit into those slots even with the clamp off and I checked and compared the dimentions of the old to the new and the new being 009 is a little wider at the top but with the clamp wider it should fit but d..n I just can't get it into those slots and sometimes it feels like it is right in the slot but then I am able to still turn it when I put the rotor back on.
HELP !!! My fingers are all cut up and sore from yesterday but I'm not giving up...
I am really glad I have this place to talk to you guys
that have answers that just might work !!!

LINDA

Gunngee · #10 05-21-2004, 08:57 AM

I don't know what else to say except maybe double check that it's not the rotor thats turning instead of the distributor. Did you check the length of the shaft against the old one? I'm at a loss for suggestions this is all I can come up with. Maybe all the fresh air I get from going fishing for the weekend will jar something in my brain. Good luck and don't give up!!!

Doug Rodrigues · #11 05-21-2004, 05:06 PM

Linda,
Go buy one of those cheap plastic calipers from a cut-rate tool store. You can probably buy one for 2 bucks. Measure the old and new distributor shaft housings. If you don't have the old original distributor, measure the diameter of the hole and the width of the shaft housing. There should be about .002 to .005 (thousands of an inch) clearance. If you don't have any clearance, a 10 pound sledge hammer may help. JUST KIDDING !!

I agree with Gunngee: If there is clearance but you still cannot get it pushed-in.....

then it's beyone by imagination what the problem could be. Maybe you need to smear a bit of vaseline around that O-ring seal? OR...maybe if the seal is very hard you may need to soften it up by heating it with a hair drier first, then using vaseline and then shoving it in? If these aren't your problems, then someone more knowledgeable has to inspect it to determine what the problem is? Other than the wrong size shaft....there is really nothing else to keep it from going-in. Does the key on the shaft look like it's designed to fit into the slot in the hole?

Lindacars · #12 05-22-2004, 01:14 AM

Hello Guys, it's Linda again and again!
Yes, I have the old one, and I also have one question for now...
The old one had the rubber O ring in the middle of the dist. and when I got the new 009 it was on the bottom of the dist. so I put it on the middle of the dist. where the groove is (like the old one). Does this make a differents? It would not even go in at all with it on the bottom!!! Was this OK???
I'll be working on the bug all day Saturday and will check for info from you.

Yes, lots of luck for me.
LINDA

Doug Rodrigues · #13 05-22-2004, 01:21 AM

Just make it exactly like the original, and everything should be okay.

Lindacars · #14 05-22-2004, 02:38 PM

OK Guys,
Now stand up and shout because I finally figured out what was wrong,
WoW, do I feel stupid...

The notch on the bottom of the dist. is not exactly in the center,
it is off-set so that the dist. will ONLY go in one way.

BUT, now that I figured this out and the dist. is in and nice and snug .
BUT NOW that the rotor is aligned with the notch on the top of the dist. housing where it would be at #1 spare plug, It is facing towards the front drivers side of the car and NOT the rear as it should be.,
and the groove in the crankshaft pulley is aligned with the seem in the crankcase now...
Isn’t it suppose to be facing the rear???
If I was to turn the crankshaft till the rotor is facing the rear and align the notch on the top of the dist. housing wouldn’t the notch on the crankshaft be 180% off ???

I swear I am going to complete this today..................
Thanks.
LINDA

Lindacars · #15 05-22-2004, 09:06 PM

OK Guys,
It's all done for now. Got it all to TDC and just perfect.........
The new electronic Ingition kit; Pertronix Ignitor II and the Pertronix Flame Thrower II Coil are all also installed now finally.
THANK YOU ALL SO MUCH FOR ALL YOUR HELP...
I COULDN'T OF DONE IT WITHOUT YOUR THOUGHTS.
Linda

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