2.5NA replacing timing belt, and now can't move crankshaft

[evanmc]

1985 2.5 NA 110

I've done this before successfully, but managed to mess up things completely this time

After aligning the timing marks for the crankshaft, camshaft,  dps and fitting the belt, something must have slipped when I was rotating the crankshaft by hand, and now I a left in a situation where:

- The camshaft points at the timing mark, but the crank mark is at the 3 o'clock position.

- The crankshaft can't move -- i feel solid resistance (no pin in the flywheel at this point)

How can this be remedied?  I was trying to move the crankshaft with the timing belt off when I encountered this.

Can I manually move things back into alignment?

Thanks,

-Evan-

[monkie]

I think the safest way to do this is to get the valves to close by loosening the rockers. Then you are safe to move the sprockets back in alignent with the timing marks.

[western]

As above remove or slacken off the rocker shaft, then remove belt,tensioner & reset the cam & crank to the timing marks obviously make sure number 1 & 4 cylinders & valves are TDC before refitting the belt 

[evanmc]

OK, I'll take take that approach.  Do I actually need to remove the rocker shaft, or can I just loosen it a bit and move the crank and cam by hand?

[western]

if you slacken the rocker shaft pedestal bolts fully then you should be able to carefully rotate cam & crank, when you move the cam just make sure no pushrods get caught up & jam on the rockers.

[evanmc]

that did the trick. thanks.  btw.  the best I seem to be able to manage on the timing belt is about 1/2 tooth off.  will this be a problem?  Also, do i have to re-do the tappets if i loosen an then tighten the rocker?

[western]

its worth a re check just for peace of mind, glad it worked,  once initial tension is done, rotate 2 full turns & recheck tension of timing belt, IIRC that's what the workshop manual states

[monkie]

Glad it got you out of trouble. 2 turns of the crankshaft (clockwise) is what I do, so that the the camshaft and injection pump have made 1 turn then double check the tension of the belt and nothing has slipped out of alignment. Yes, you are going to have to recheck/adjust the tappets once you have tightened down the rocker shaft.

[Snagger]

I would suggest you remove and inspect all the valve push rods to make sure you haven't bent any, and check their seats in the cam follower slides for the same reason - the reason that the crank shaft wouldn't rotate it that the pistons were pushing hard against the open valves as the timing was out.

[monkie]

^^^good advice above. The rods are desgined to give. I have done this in the past and managed to bend a push rod, its not as hard to bend a rod as you might think.