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General Automotive General automotive discussion. This is intended to be a discussion about other not VW and Diesel cars you may have or interested in.

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Old July 11th, 2011, 12:23   #16
visionlogic
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Thanks for the input guys.

The problem with the intake cam gear is that it will not "rest" in the position where its alignment marks are horizontal - it wants to either rotate forward or back and then come to a "rest". The exhaust is similar but not as bad. Perhaps wooden wedge(s) behind each gear will supply the needed "drag"... I'll just have to try something.
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Old July 11th, 2011, 13:36   #17
TDIJetta99
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not behind the gears.. between the 2 gears...
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Old July 11th, 2011, 21:21   #18
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. no need for the piece of wood. the tension of the belt will probly pull it back . here is a good how to from the SRT-4 same motor and idea just no turbo on yours

http://www.srtforums.com/forums/f75/...r-head-421718/

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Old July 12th, 2011, 05:15   #19
visionlogic
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Quote:
Originally Posted by AndySRT View Post
. no need for the piece of wood. the tension of the belt will probly pull it back . here is a good how to from the SRT-4 same motor and idea just no turbo on yours

http://www.srtforums.com/forums/f75/...r-head-421718/
I am familiar with putting the exhaust cam a 1/2 notch below the intake cam to allow the tensioner tightening to pull them into alignment.

However, the linked post says to loosen the idler pulley and install the belt around it last. That is different from other instructions which say to begin at the crank and wrap the belt around countrclockwise and end at the tensioner. Interesting. Thanks!
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Old July 25th, 2011, 07:54   #20
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Maybe success. Yesterday, after having the belt on and off a dozen times or so, each time slightly varying the relative positions of the 2 cams and the crank, the stars aligned so that cam and crank marks finally positioned properly when the tensioner was set correctly. Rotated crank twice around and they remained aligned. Hooked up the battery to test - started instantly, ran it for 5 secs and shut it down. Too tired to do any more now. Too much sun and heat have baked my brain.

I still don't know the trick of getting the belt on easily. No matter how I swung the tensioner through its loosen-tighten arc I could not find any position that would allow the belt to go over it as the last step. And removing the idler pulley and attempting to reinstall it as the last step wouldn't work either - still not enough slack. I ended up installing the belt on the exhaust cam as the last step - carefully using a small flat blade screwdriver to pry the belt edge on until it slipped into place. Each time I inspected the belt and I did not see any damage done by using this method. I guess only time will tell.

All in all, a truly cussworthy endeavor.
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Old January 7th, 2012, 09:05   #21
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The idler trick worked like a charm for getting that belt back on. I messed with it for hours and it just wouldnt go. Thanks for the ideas. A truly helpful thread. I just had to create an account to tell yall!
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