simpe job gone wrong(cambelt)

duncancallum · Post by **duncancallum** » Fri Sep 10, 2010 7:21 pm

before some onew thinks i am a compleate idiot I have done countless belts before and worked as a mechanic 10yrs ago and still work in the motor trade. I do all my own work from engine building to spraying and about did the head on my 2.0td MG which runs 2 timing belts after the cambelt snapped before its intervall . I just wanted to do the belt befrore pressing the rocco in as my dailey driver as I have my headgasket to do on my 1.4 diesel 106.

So how can a 1/1.5 hour job go wrong heres how;

right went to do the timng belt on the gt11. the bottom pulley was seized to the sprocket so rather than knacker the pulley as its a bit thin and rusty I decieded to pull the sprocket off to drift the pulley of with out damaging it.

This is where its gone horribly Pete Tong.

The bottom bolt I know is tighted by Hans at the factory to FT and then some. so I chocked it all up and got the big bar on, this didnt go as planned. the clutch slipped and threw my timing out.(not so much of an issue yet).

The bugger came off so off to the kettle for a brew i pulled the sprocket/pulley assembley off and worked the tin pulley off. It was at this point I noticed the keyway on the sprockey had sheared. Buggeration.

I have a new sproket of the same part number from Tps I have fitted this and the spacing of the bottom pulley to the water pump is now out. the alt and water pump are fine

I dont know if it was out before as i didnt check I just pulled the belt off. So heres my questions:

1) should the water pump pulley have a spacer behind it or are there difrent bottom pulleys?

2) can some one tell me where all the factory marks are as I will have to static time the whole thing from scratch rahjer than relying on my paint marks.

3) Why do simnple jobs just drive you to drink?

PS its not all in vain the belts showing signs of micro cracking and the tensioner has more play than a 8wk old spaniel

ChrisPears · Post by **ChrisPears** » Fri Sep 10, 2010 9:24 pm

1) Don't think so.

2) Static marks...theres a mark on the crank pulley and the intermediate, these should point at each other, and the cam should be inline with the join between the head and the block (at the front of the engine).

Pull the dizzy cap off and check that the rotors pointing at #1 just for good measure.

3) Bloody Volkswagens...

duncancallum · Post by **duncancallum** » Fri Sep 10, 2010 9:33 pm

cheers dude

Ill have squint in the morning

bmseven · Post by **bmseven** » Sat Sep 11, 2010 4:27 am

It all in the faq
http://sciroccoregisterforum.co.uk/faq/ ... oil-seals/

duncancallum · Post by **duncancallum** » Sat Sep 11, 2010 6:42 pm

Right had another quick squint today(I am in the middle of gutting my new house so time on the rocco is limited to inbetween bouts of DIY and the weather).

The bottom pulley is hugely distorded. I presume by some one knocking it off whilst still on the car (this is what I was trying to avoid).

So I now need a bottom V belt pulley, this then will solve my issues (well car related ones anyway) and I can time it back up.

Cheers for the help dudes

PS a part numer or a gsf number would be ace I cant find it on there website

MikeH · Post by **MikeH** » Mon Sep 13, 2010 7:51 am

duncancallum wrote:
I dont know if it was out before as i didnt check I just pulled the belt off. So heres my questions:

1) should the water pump pulley have a spacer behind it or are there difrent bottom pulleys?

2) can some one tell me where all the factory marks are as I will have to static time the whole thing from scratch rahjer than relying on my paint marks.

3) Why do simnple jobs just drive you to drink?

That's always the joy of doing a job for the first time on a 'new' car - finding out whether the previous owner had ever heard of copper grease, washers, or a torque wrench.

Anyway, it sounds to me like the TPS gave you the wrong sprocket. 16v ones are about 10mm(or slightly less?) thicker. Have you measured your new one against the old one?

When timing on factory marks, I prefer to use the flywheel for the crank mark because damper pulleys can twist around their rubber centre part, and the flywheel is more accurate. BEWARE the mark on the cam pulley that lines up with the top edge of the head, is a punch mark on the engine side of the pulley, not facing you as you look at the other marks. Pull the cam cover off and check that both cam lobes on No1 are pointing up, and double check the dizzy timing (centre of rotor arm should be on the little notch in the dizzy)

As you probably know, the bottom pulley and intermediate will move when you tighten the tensioner, so I offset them by about 1cm, and usually they come into line when you tighten - with a bit of trial and error.

I've got a spare bottom pulley or two if you need them. PM me.

duncancallum · Post by **duncancallum** » Mon Sep 13, 2010 12:10 pm

Right I am confused

Its got a solid vbelt pulley on. Should it have a damped pulley then.

the bottom sproket is the same as what came off. this however doesnt mean its right.

got any part no's mate and I can check the ones I have got.

Cheers

MikeH · Post by **MikeH** » Mon Sep 13, 2010 2:50 pm

I'm confused too. A picture might help at this point :D

duncancallum · Post by **duncancallum** » Mon Sep 13, 2010 8:00 pm

Ill get a couple pics up tomorrow with a bit of luck, one of the pulley and one of the alignment issues

MikeH · Post by **MikeH** » Tue Sep 14, 2010 8:50 am

This is a PAS one - but the non-PAS ones look similar - just not quite as thick. I'm fairly sure I've got one in the garage, just need to squeeze in there and find it.

Part number (from VAGCAT.com) is 026 105 243B (non PAS) or the same part number with a C suffix for PAS

duncancallum · Post by **duncancallum** » Tue Sep 14, 2010 6:45 pm

Hi

Sorry for the phone quality.

Hope these help.

the belt centre line is about 2.5CM from the back of the pulley
http://s673.photobucket.com/albums/vv92 ... %20pulley/

MikeH · Post by **MikeH** » Tue Sep 14, 2010 9:30 pm

Belt centre line is about 17mm on mine, and outer edge is 22mm, which I think is slightly deeper because it's a PAS one.

I looked for a non-PAS one earlier, but didn't find it. I'm sure I've got one (or more) but finding it is another matter.

Can you see a part number stamped on yours anywhere? It looks like the outer half of the double PAS pulley - it would slot into the outside of the one I posted a picture of.

duncancallum · Post by **duncancallum** » Wed Sep 15, 2010 12:11 pm

Those dimensions sound far nearer.

Ill have one off you mate how do you want to sort it.

PS what rocco's/mk1s had power steering?

MikeH · Post by **MikeH** » Wed Sep 15, 2010 2:10 pm

It's a Mk2 Golf PAS pulley, although I think some later cabbys might have had PAS, and maybe US Spec Sciroccos.

I'll try to find one that's got the Non-PAS Part number.

duncancallum · Post by **duncancallum** » Sat Sep 25, 2010 5:48 pm

It runs

What a cock up of a job a the last pesron has made Dizzy was way out as was the intermiedate shaft.

He got the timing out and just moved plug leads round instead of sorting it propery no wonder nothing lined up!

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