Timing mark help needed

[motah33]

I've got MKII Golf GTI 1.8/8v (PB). After managing to get the crankshaft pulley off I could see timing mark on the intermediate sprocket.

If I line up the notch on the crank pulley with the the arrow on the lower timing cover, then the notch on the camshaft sprocket seems to be inline where the rocker cover sits and the rotor arm is lined up with its notch. However, if I remove the lower timing cover, the notch on the crank pulley is not in line with the notch on the intermediate sprocket. If the notch on the  intermediate sprocket is at '12', then the notch on the crank pulley is around '10'. I haven't checked the marks on the flywheel - not sure how to remove that green plastic covering which seems to be screw type.

I haven't removed the timing belt (yet). I've been just been turning it by hand to see where the marks are at, and if everything lines up, before removing the belt. Is the timing out?

Thanks

[Sgt_Lemon]

I chose to ignore entirely the intermediate sprocket and anything down there tbh. Firstly remove the spark plug from piston one. Take the cap off of the flywheel cover. Crank the engine until piston 1 is at tdc, this can be checked by looking for the notch on the flywheel. A good way to turn the engine is to put it in second and take off the handbrake, you can then rock the car back and forth until the piston tdc is perfect lined up with the mark on the bell housing. Now loosen the tensioner and the remove the dizzy. With the belt off spin the dizzy by hand till it points toward the notch on the far edge of it. With the belt off spin the cam round until the punch mark to the inside edge lens up level with the level of the head/rocker.

Put it all back together, cam belt wants tension to allow a 90degree twist with two fingers, not super loose or bow string tight. Then get the timing gun out and use rubjonnys guide on the maintenance section to set the ignition timing to 6degrees

[motah33]

Thanks for the info.

Is there a good way of removing the green plug on the gearbox for checking the flywheel marks? The car is on an axle stand at the moment with quite a few bits removed. The car is in neutral and I turn the engine via the crankshaft bolt. The spark plugs are out.

With the belt tensioner loosened, does the dizzy and the camshaft spin freely? Just trying to get a feel for what moves. I've read the guides, forums etc. and some lock the camshaft, put it in gear to stop things moving, use tippex to mark the belt before removing and replacing - that's assuming the timing is right to begin with. I have seen pics of all the marks lining up including the intermediate sprocket one's as well. I'm curious as to why it's out.

I do have a timing gun but I'm a long way off from starting it up as there is still quite a bit to do on it but I do want to get a feel of how it works.

[Sgt_Lemon]

I got lucky with the green plug and had a stud extractor socket with the correct size head to remove it. A screwdriver will probably do it. You need the belt off the cam to spin things freely also.