Oh joy... MORE fun!!

[tbones]

Hey gang,

Well, what’s that old adage...

if you want something done right, do it yourself!

I paid some supposedly decent mechanic to do a full timing belt job on Sunny before I took off for Utah. Well, I come to find out He didn’t set the pump timing, and sort of half-assed it back together.

I have needed those 30mm shims to try properly align the water pump pulley and power steering pulleys, So as to not wear out the V belt, so I tore into that wuick and easy project early this morning.I expected this job to take about 30 minutes.

I was wrong!

The mechanic torqued those 6 mm Allen head bolts WAAAAAYYYY over the recommended amount (18 ft/lbs?) To the point where, after strippiing out the Allen heads I resorted to heat and drilling and chisels. Many hours later, after FINALLY getting the 3 bolts out, and ruining the nice new water pump, I find that I will basically need to do the complete timing belt job again. This time I will do it myself!

A few quick questions here:

1. Has anyone improvised a way to remove the camshaft sprocket without the proper tools? I was planning to purchase these tools but did not get around to it(since I PAID someone to do it for me, I didn’t think it was urgent!) Unlike my old 1.6, I don’t seem to have a way to hold the sprocket in place while I loosen the bolt

2.my extra timing belt is New from Contitech, but has a date of 4/2015, as I bought it for a spare. Would you all put this brand new but at least five year old belt on your tdi?

Thanks again for everyone’s help with my issues!

Regards
Steve

 

[Steve Addy]

Sorry to hear of your woes with the mechanic work, a lot of times it's hit or miss with that...mostly miss in my book.

I use a cheap HF 'holding' tool for camshaft, it works but I think I modded it a little maybe. Highly recommended not to try it with a cam lock plate, that can break the other end.

I would probably use the timing belt but that's just me. I have used older ones than that but not on any vehicle I've worked on for someone else. I'm not actually sure where the dates are on those. Seems I have a new conti belt that's older than that on the shelf right now.

Steve

 

[Windex]

You can remove the cam pulley by striking it from the rear with a punch. there is a plastic casting mark in the rear timing belt cover that lines up with the edge of the belt pulley. Carefully drill that out with a 1/4" bit and use a 1/4" drift to knock the pullet off (once you have loosened the cam bolt a few turns).

 

[tbones]

hey Steve,

thanks... I have a friend who may lend me his tools, but he has to get them back from some OTHER friend first... Ill take a look at the HF crap, and see if it'll do the trick in a pinch

I may call Contitech tomorrow and ask their opinion on how old a belt can be before it's too old to install

thanks again!

Steve

 

[tbones]

hey Windex!

Thanks... it's the BOLT I need to loosen... sorry if i didn't make that clear. (the old belt is off now, and I need SOME way to hold sprocket while trying to loosen the big bolt). I do know better than use the cam locking plate

regards,
Steve

 

[MOGolf]

A length of 2x4 with two grade 8 bolts through it.

 

[tbones]

thanks MOGolf

I may try that tomorrow!

regards,
Steve

 

[ToddA1]

I just use an impact on that cam bolt. Pops it right off.

I’ve removed many stripped hex bolts with Irwin bolt outs. Makes it too easy.... I have the smaller set, but looked into the larger set.

My buddy said the $30 HF set worked fine for him.

-Todd

 

[tbones]

hi Todd,

I borrowed a local TDI club member's tools and made short work of it.

thanks,
Steve

 

[Bob S.]

Glad to read that you got the done.

 

[tbones]

thanks again Bob!

Now I've replaced the IP, and and trying to chase down some electrical gremlins.

I Still need to get my Rosstech VCDS to work... it's a computer issue, not a Rosstech issue as far as I can tell.

I leave early morning Thursday for KW... towing my O'Day Mariner down behind Sunny... wish me luck!

I haven't had a chance to get up to my storage place to get pix of those seats you wanted yet... when I return I'll make it a priority!

regards,
Steve