90 bhp tdi horror - Help - More with pics

[jezza16v]

Not yet, have to get those mk2 out of the garage, so we can get this one in, red one is work in progress, should be on to it this weekend hopefully. Can't be bothered doing tricky stuff outside, just too cold & wet atm.

[jezza16v]

OK, took the camshaft cover off and the flywheel plug out to check the timing.
The camshaft was only 1 tooth ahead of the crank pulley and the injector pump six teeth ahead of the cam pulley, so lucky us! Seems like no damage to the valves........so why was this......well, when the aux belt tensioner disintegrated one rib of the aux belt was stripped off and got wrapped around the back of the torsion damper and then dragged into the crankshaft cambelt pulley, spun around and chewed up disintegrated and sent around the other pulleys so no wonder a few teeth were skipped.

This is what I found behind the torsion damper


This shows the smeg behind the torsion damper, the plastic cover looks thick with grease, but its not, the plastic is scored and melted, I guess by the shredded aux belt!


This shows shredded bits squished into the cambelt teeth.


This shows a scuffed belt tooth where it has slipped.


This shows a piece of aux belt stuck in the cambelt idler pulley.


This is that piece pulled out, you can see the imprint of the cambelt teeth in it!


We thought that the previous owner had put a five rib aux belt on, the new one we put on was six, clearly the old one was a six rib, but 1 and a half ribs had been shredded off. So It looks like we got off lightly, a good clean up, new cambelt and tensioner & re-time and away we go. Will be next weekend now so will let you know how it goes then.

[Wayne]

Nasty, fingers crossed

[jezza16v]

Just put a new cambelt on this morning and it runs a treat, no valve damage at all. Phew!   

All that grief and effort just because the aux belt tensioner pulley broke up.........for a few quid, if you've got an aux belt and tensioner pulley that's been on a while, suggest you get them changed. On this one I reckon the tensioner pulley was original (125k), not sure about the belt. The main reason it failed was because water got into the bearings and rusted them out, there were no bearings left in it, just the inner race and the outer plastic wheel which fell off and let the belt go.

[FlySpeck]

nice one mate, sweet

[Matty-MK3]

Great result.

Every service I take the pulley off and grease it up, then grease any other pulleys  as well because of this very reason!

[pablo64]

glad you got it sorted, and thankfully no serious damage, nice one mate