DeafBug
Gone but Never Forgotten: Requiescat In Pace
BEW TB and Tensioner question (long) Video added
This post is for the experts only, those that have done the BEW timing belt. Everyone is welcome to read but I like to keep the replies for the experts.
I printed MOGolf's BEW Timing belt change instrustions.
I printed ALLDATA's timing belt instructions.
ALLDATA's instructions contained additional information that MOGolf's instructions didn't. I will point out the difference here as that is my problem.
First of all, I did take a mental image of the tensioner that was installed on the car before I even started messing with the belt. I also note how was it set if you when I put the tensioner tool. I noticed that the tensioner that was in the TB kit didn't have the pin installed. (MOGolf told me that it should be in place already with the PM I send him.) I thought I could reset the tensioner and install the pin before installing the belt on the car. It wasn't hard and it didn't sound a biggie. Now I am not sure if it was a mistake or is the new tensioner bad.
I also have a few questions that I am confused as it doesn't make sense to me. I will point that out as I go.
All instructions here are copied from the ALLDATA whether or not it is also included in MOGolf's instructions. Keep in mind that the pictures are not actual when explaining the instructions. They are what is on the car right now except one.
When the new tensioner is insert on the stud and the belt is in place ready to be set. The following instructions said.
Remember the counter-clockwise and stop part. As I will explain later.
Then I got the belt on completely set the tensioner as instruction after I managed to get the tensioner locked down with the locking pin that it came with (remember pin was not installed.)
I turned the engine over twice. I wanted to verify that I could still locked it down as mention in the instructions.
I could not insert the pump pin in the camshaft (called hub in their instructions) So I continued on the instructions on how to correct it or set the what I think is the timing. So the following instructions as stated is what confuses me.
The rest of the directions doesn't make any sense as it assumes that there is no tension or you still have some play on the enlonged slot. It mentions about turning it backward 1/4 turn!!! Just how?
Okay, now you can see why I was very careful when I turn the engine over twice as I am near completing the second rotation. Simply to avoid from having to turn it back. (I can read DBW mind on how you may pop the crankshaft bolt loose. ) The best thing is that the dimple on the crankshaft pulley is exactly the same as the A4 or the A3 or B4. So it was very easy to tell when you are at or about TDC.
But I had to turn it slightly forward to get the pump pin inserted, then I move it slightly back to get the crankshaft stop (tool) inserted. I did this 3 times. After the third time, I had to stop and analyzing what was happening. And why is the tensioner still screwed up. Here is the picture of the tensioner AFTER turning the engine over twice and inserting the pump pin.
You can see that the V tab is far off from where it should be on the right side. Actually this is in the resting position of the tensioner. I don't think it is creating any tension but the belt is still snug.
Below is the picture while the pump pin is insert and I have slightly moved the engine back to install the crankshaft stop (tool) It did create a little tension.
I still think there is something wrong but I am not sure what it is. I am going to the dealership in the morning and get a new tensioner, hopefully the pin is in place. And I do plan to (if I can) to ask the mechanic about the counter-clockwise fully on the camshaft pulley and then attempting to turn the engine backward 1/4 turn as mentioned in the instructions which to me seems impossible as it already hit the end of the enlonged slots.
Even with the camshaft bolts loose, as mentioned, you still can NOT turn the engine backwards since it is already at the end. Where does the 1/4 backward turn come in?
I am not going to do any more work on it until I have answers.
Why do we need to fully counter-clockwise the camshaft pulley prior to installing the belt and insuring it is still fully at the end of the slot?
Why is the tensioner not creating tension? My mental image of it before doesn't match what it is now.
Is the tensioner really defective as the locking pin was not in place when I open it?
Are those instructions by ALLDATA crap?
If the experts wants a copy of the ALLDATA instructions, email me. I know your names so other curious ones will be ignored.
This post is for the experts only, those that have done the BEW timing belt. Everyone is welcome to read but I like to keep the replies for the experts.
I printed MOGolf's BEW Timing belt change instrustions.
I printed ALLDATA's timing belt instructions.
ALLDATA's instructions contained additional information that MOGolf's instructions didn't. I will point out the difference here as that is my problem.
First of all, I did take a mental image of the tensioner that was installed on the car before I even started messing with the belt. I also note how was it set if you when I put the tensioner tool. I noticed that the tensioner that was in the TB kit didn't have the pin installed. (MOGolf told me that it should be in place already with the PM I send him.) I thought I could reset the tensioner and install the pin before installing the belt on the car. It wasn't hard and it didn't sound a biggie. Now I am not sure if it was a mistake or is the new tensioner bad.
I also have a few questions that I am confused as it doesn't make sense to me. I will point that out as I go.
All instructions here are copied from the ALLDATA whether or not it is also included in MOGolf's instructions. Keep in mind that the pictures are not actual when explaining the instructions. They are what is on the car right now except one.
When the new tensioner is insert on the stud and the belt is in place ready to be set. The following instructions said.
Turn camshaft pulley in elongated holes counter-clockwise in direction of
arrow - onto limit stop. Install toothed belt to crankshaft pulley, belt tensioner
and camshaft pulley.
Remember the counter-clockwise and stop part. As I will explain later.
Then I got the belt on completely set the tensioner as instruction after I managed to get the tensioner locked down with the locking pin that it came with (remember pin was not installed.)
I turned the engine over twice. I wanted to verify that I could still locked it down as mention in the instructions.
Okay, I did be careful not to turn too much when I am near the end of the second rotation of turning the engine over. I managed to slowly advance the engine until I could get the crankshaft locked down. (Did I do something wrong here?)Note:
- Turn crankshaft two rotations in direction of engine rotation and set again to TDC No. 1 cylinder.
- As this is done, the shaft of the crankshaft stop must be able to engage in the sealing flange from direction of engine rotation.
- If the crankshaft is turned past TDC No. I Cyl. and the crankshaft stop could not engage in the sealing flange, turn the crankshaft back 1/4 turn to be able to turn the crankshaft in the direction of engine rotation again to set it to TDC No. I cyl. It is not permitted to turn the engine opposite to the normal direction of rotation when turning to ensure the crankshaft stop will engage.
- Once crankshaft stop T1 0050 has engaged, check whether hub can be fixed in place using locking pin 3359
I could not insert the pump pin in the camshaft (called hub in their instructions) So I continued on the instructions on how to correct it or set the what I think is the timing. So the following instructions as stated is what confuses me.
So I did, the owner of the TDI help me on that one. He put his finger on the pump pin as I had placed it so that it should slide right in when it get in place. I was under the car, turning the crankshaft bolt forward (in the direction of the engine rotation) until he got the pin fully inserted. I could see it from underneath as I looked up.Pull crankshaft stop pin out of hole in sealing flange and turn crankshaft until hub can be locked with locking pin.
That is what I am SO confused on. Just how do you turn the engine backwards when you have the pump pin insert and the bolts all the way at the end of the enlonged slots. Look at the picture above.
- Loosen camshaft pulley securing bolts
- Turn crankshaft slightly against direction of engine rotation until crankshaft stop pin is positioned just before hole in sealing flange
The rest of the directions doesn't make any sense as it assumes that there is no tension or you still have some play on the enlonged slot. It mentions about turning it backward 1/4 turn!!! Just how?
Okay, now you can see why I was very careful when I turn the engine over twice as I am near completing the second rotation. Simply to avoid from having to turn it back. (I can read DBW mind on how you may pop the crankshaft bolt loose. ) The best thing is that the dimple on the crankshaft pulley is exactly the same as the A4 or the A3 or B4. So it was very easy to tell when you are at or about TDC.
But I had to turn it slightly forward to get the pump pin inserted, then I move it slightly back to get the crankshaft stop (tool) inserted. I did this 3 times. After the third time, I had to stop and analyzing what was happening. And why is the tensioner still screwed up. Here is the picture of the tensioner AFTER turning the engine over twice and inserting the pump pin.
You can see that the V tab is far off from where it should be on the right side. Actually this is in the resting position of the tensioner. I don't think it is creating any tension but the belt is still snug.
Below is the picture while the pump pin is insert and I have slightly moved the engine back to install the crankshaft stop (tool) It did create a little tension.
I still think there is something wrong but I am not sure what it is. I am going to the dealership in the morning and get a new tensioner, hopefully the pin is in place. And I do plan to (if I can) to ask the mechanic about the counter-clockwise fully on the camshaft pulley and then attempting to turn the engine backward 1/4 turn as mentioned in the instructions which to me seems impossible as it already hit the end of the enlonged slots.
Even with the camshaft bolts loose, as mentioned, you still can NOT turn the engine backwards since it is already at the end. Where does the 1/4 backward turn come in?
I am not going to do any more work on it until I have answers.
Why do we need to fully counter-clockwise the camshaft pulley prior to installing the belt and insuring it is still fully at the end of the slot?
Why is the tensioner not creating tension? My mental image of it before doesn't match what it is now.
Is the tensioner really defective as the locking pin was not in place when I open it?
Are those instructions by ALLDATA crap?
If the experts wants a copy of the ALLDATA instructions, email me. I know your names so other curious ones will be ignored.
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