Adjustable CAM Pulleys + Distributor Re-location

8th August 2004

Hi this story describe the issues I overlooked when modifying the adjustable cam pulley with the distributor relocation.

1st, the exhaust cam pulley was sent to Ah Ming (friend - occupation machinist) for modification. It took very long time because he was busy. Finally got it yesterday. It has +/- one teeth range of adjustment. Immediately go to his house at night to install it, but cannot this cannot that, so while talking and discussing, I started removing cam pulley cover, middle cover and spark plugs cover. Then gatal (gatal is a Malay word means itchy in English) remove the distributor and finally the distributor relocation kit.

Only then Ah Ming realize there's two missing holes on the new adjustable cam pulley to support the distributor relocation kit, so tonight cannot install for sure, must wait until tomorrow, go to workshop, take out existing modified cam pulley and take it to machine shop and immediately copy the two holes onto the new adjustable cam pulley so that it becomes adjustable + relocation.

It is also this time that we realized that the distributor physical angle is determined by the grove on the relocation kit, which is then determined by the two holes supporting the rotational grip of the relocation kit. It was lucky that last time we didn't realize that but it worked. i.e. enough range to set the distributor timing. Distributor does not end up - upside down......

This time, I purposely ask Ah Ming to shift / rotate the two hole points so that my distributor sits right-up like everyone else. Ah Ming says to move two teeth, but I say four teeth. So four teeth it is shifted.

So, today things worked out as planned, go to workshop, take out old pulley with modified relocation two holes, go to machine shop, copy and modify onto new adjustable pulley, go back to workshop and install the new adjustable + relocation. Lucky no need to open timing belt tensioner. Managed to put in....fine... thanks to sifu master samurai yoga, anzacs02 @ patrick and Ah Ming.

Start ..... cannot start... wahhhhhhhhhhh, so scared now .....

I argue the relocation kit was installed 180 degrees wrong, so distributor cannot measure correctly. Then so hard to take out the so tightly fit relocation kit..... check, not wrong. :( - me wrong guess.

Then Ah Ming blame the four teeth rotational shift too much, distributor set at maximum but ECU thinks negative, worst than minimum...., distributor relocation kit's bracket not enough range to turn the distributor as high as I wanted to. :(

Finally found out I install the 1-3-4-2 spark cable combination wrongly, so set it back correctly. Can start, but idling bad, 600 rpm, difficult to breath....., drives very bad,,,

Then found out the four teeth rotation shift, really too much, but I couldn't care less, it's 3:30pm I had to go home, cut hair and all..

At this stage, adjustable cam at ZERO, distributor max. After reached home, open bonnet let it cool, shower, rest....

7:30 pm ADVANCE one full teeth, car immediately idles at 1,500 rpm :) hehehe very happy, then retard distributor timing until 900 rpm. This is done on purpose because I know the car can idle properly. But don't know how bad is the power..

Don't care, Ah Ming call me to go his house to check his cam's pulleys. So I go. During the drive to his house. Completely no power. Lost all street drivability.

Reached Ah Ming's house. Count his pulley teeth, 46, therefore 360 divide by 46 = 7.9 degrees. So, half teeth is 3.9 degrees

Since cam turns 2 rounds for every one round of crank, so crank is 2.9x degrees. Wow that's allot.

20v has 36 teeth, so no need to use calculator also know it's 10 degrees per teeth. So this is what I was using to drive to Ah Ming's house - like shxt. I think human running also faster than my car.

Once all this are found, issues of distributor not enough range mentioned to Ah Ming, we start work to correct all the problems .....

ADVANCE was quickly reduce from 10 degrees to 2.5 degrees = 1/4 teeth shift. But still remains in ADVANCE.

Power immediately came back, timing out of sync allot again, reset timing. Drive out for dinner with Ah Ming, car feels much better, nearly back to normal, but seems like not as powerful as before...

After dinner go back to Ah Ming's house, RETARD 1/4 teeth = 2.5 degrees. But in accuracy, I think only managed 2 degrees - not even 1/4 teeth.

Anyway, set distributor timing highest, start car - 600 rpm. The four teeth shift problem come back to haunt me :( So, take out distributor relocation kit's bracket and drill, grind, cut, modify. Take out, install, test, repeated four times or more....

Finally complete 11:30 pm. Drive home. Don't know is it psychological, got a bit better. Not a hell lot. Well, if Ah Ming RETARD 3.9 degrees intake and exhaust, then may be I should go 4/10 teeth also = 4 degrees.

 

  1. Adjustable CAM Pulleys
  2. Adjustable CAM Pulley + Distributor Re-location

 

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