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Thread: ABF timing belt and marks

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    Default ABF timing belt and marks

    I am a total novice putting an ABF in my Mk1.

    I have removed the ABF from the donor car and now have it on my engine stand. I took the top part of the belt cover off as i'm thinking i might as well change the timing belt as the engine is out. I'm glad i did, i'm no expert but this doesn't look good to me



    The lower pulley is in line with the mark on the cover



    so why is the top timing mark here? Shouldn't 1 and 2 line up?



    I took the distributor cap off to make sure the engine was at TDC (I read Haynes) and the rotor arm is also 180degrees out. Will this have done any damage? Or am i being a total and utter idiot?


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    For every turn the cam(top end) turns the bottom end turns twice, so turn the crank 1 whole turn and the top will line up.
    The top pulley is twice the size of the bottom.
    So yeah, your being an idiot , but you'll get there

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    This caught me out for about 2 weeks

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    Looks like the mystery is solved then Shaggy.
    I reckon Scooby Doo cold have helped you out with that one for a Scooby snack or two.
    Last edited by danster; 29th April 2011 at 18:34. Reason: pic

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    Anyone got a hole i can hide in

    Cheers, just need to change the belt now.

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    Right, in for a penny, in for a pound

    I have rotated the lower crank pulley one turn and now have the timing mark as shown below. It is one tooth out



    I have done a search and it looks like people say to put the belt on one tooth out anti-clockwise so that when you tighten the tensioner it brings it clockwise to be spot on, have i read this correctly?

    Or am i babbling again I know if i fudge this bit up it's not good, so want to get it right

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    looks like it

    should be like this

    http://www.clubgti.com/forum/showthr...ht=abf+cambelt

    you using the flywheel mark?
    Got an M3 instead

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    as above dont use the crank pulley mark, use the flywheel mark. i worked on an AGG where crank pulley mark was out by 90 degrees!
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    quote RJ, my crank pulley was out too. very strange.

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    Sorry to sound stupid.

    I have removed the flywheel but i know where it was when i removed it! How and what do i line it up with, there are no marks and i have the gearbox off at the moment.

    I've marked the belt and both top and bottom pulleys so i know where they are at the moment but the top pulley is out by one tooth clockwise!

    I've ordered the tensioner (older one) and belt today from AVS with the tensioner tool for a tenner so want to put the new belt on this week, but obviously don't want to balls up my engine before i even run it!

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    Quote Originally Posted by rubjonny View Post
    as above dont use the crank pulley mark, use the flywheel mark. i worked on an AGG where crank pulley mark was out by 90 degrees!
    That is just because some doofus put it on wrong in the past. But yes, setting the flywheel to it's TDC mark on the gearbox bellhousing mark, then checking the crank pulley is the best way.

    Shaggy, you could just temporarily fit the flywheel and gearbox with a couple of bolts to allow confirmation that the crank pulley is on correctly.

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    I've got a brand new sachs clutch kit arrive today for a MK2 8v 020 gearbox so will get the flywheel off the original Mk1 DX engine.

    Will this complicate things if i put the Mk1 flywheel and MK2 gearbox on instead as these are the ones i will be using once the enigne is put in my Mk1 Golf? Or shall i put the ABF flywheel and 02A gearbox back on just to get the cambelt on first then worry about using the others after?

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    Have a Scooby snack for being correct.
    If you use those 020 clutch and flywheel parts everything will line up too. Remember the 020 flywheel has 2 dowels that need to line up with the pressure plate to ensure correct orientation.

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    Quote Originally Posted by danster View Post
    Have a Scooby snack for being correct.
    There is always a first

    So to get it straight in my head. I'll return the crank pulley to the mark on the lower cam cover with the top cam pulley mark at the top (all be it one tooth out)

    Then put the DX flywheel and 020 gearbox back on loosely and then make sure the mark on the flywheel is visible through the hole on the top of the gearbox.

    Mark the existing belt and pulleys so i know where it all sits and then take the belt off and mark the new one the same.

    I'll have to put the new belt back on but move the top cam pulley one tooth anti-clockwise so it sits correctly.

    Cheers for the help!

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    You got it.

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    Cool Thanks for your help.

    If i do balls it up can i use the method of taking the plugs out and then making sure that no1 is at TDC by sticking long think down cylinder one and watching until it rises to the top, then line up the cam pulley and the flywheel through the gearbox hole?

    Hopefully i won't balls it up

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    Quote Originally Posted by danster View Post
    That is just because some doofus put it on wrong in the past. But yes, setting the flywheel to it's TDC mark on the gearbox bellhousing mark, then checking the crank pulley is the best way.

    Shaggy, you could just temporarily fit the flywheel and gearbox with a couple of bolts to allow confirmation that the crank pulley is on correctly.
    subtract 1 scooby snack for being incorrect, the bolt holes are offset so its impossible to fit it wrong. the actual reason was the outer part of the pulley had spun round the inner part due to I assume to a dodgy damper rubber

    Quote Originally Posted by shaggyjh View Post
    Cool Thanks for your help.

    If i do balls it up can i use the method of taking the plugs out and then making sure that no1 is at TDC by sticking long think down cylinder one and watching until it rises to the top, then line up the cam pulley and the flywheel through the gearbox hole?

    Hopefully i won't balls it up
    Yep! just put cylinder 1 at the top of the cylinder while you're messing about building the engine, then once the flywheel and gearbox are on you can get it lined up 100% perfect
    Last edited by rubjonny; 7th May 2011 at 12:13.
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    Quote Originally Posted by rubjonny View Post
    subtract 1 scooby snack for being incorrect, the bolt holes are offset so its impossible to fit it wrong. the actual reason was the outer part of the pulley had spun round the inner part due to I assume to a dodgy damper rubber
    Give me the Scooby snack back! Obviously the holes in the V / serpentine belt pulley are offset. I was referring to the fact that someone will have put the timing belt pulley on wrong, ie not torqued correctly, allowing it to slip. Just the usual lazy mechanic that buzzes off the 19mm bolt when doing a timing belt, instead of removing just the allen bolts. And when rebuilding it failing to torque it up correctly.

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    there was nothing wrong with the belt sprocket, we would have had a whole load of other issues if it was damaged

    like i say, it was the outer part of the pulley which had slipped round the inner due to the rubber bit between being buggered
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    I'll wait until i get my new bits and then check i've done it ok.

    When i took the flywheel off originally the mark on it was at roughly 1 to 2 o'clock if you look along the engine from the gearbox side. Is this right? The hole in the MK2 gearbox is at the top (ie 12 o'clock)

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    you can only put the fly on 1 of 3 ways so as long as the mark is roughly at the top thats close enough for assembly purposes. there are 2 locating dowels too which help make sure you put the flywheel on the right way, but it is possible to bolt the fly on wrong and crush the dowels/bend the pp! so make sure you line these up properly
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    Just cleaned it all off and then bolted the new Sachs pressure plate on with the new bolts with loctite to 44lb/ft + 90' torque. Is this ok? Used the power steering bracket as a make shift to stop the thing turning round when torquing it



    I then have installed the cover and wire clip



    How do i now fit the clutch? How do you keep the clutch central while trying to place the flywheel over it and get the 2 pins on the flywheel into their respective notches?

    Cheers

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    No worries, had another go and got it on. It has got a small bit of play but i guess when the gearbox goes on it'll slot onto the spline and jobs a good'un


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    The friction disc will only go on one way, if you hold it in position then put the flywheel on carefully aligning the 2 locating dowels then it will still be possible to centralise the friction disc as you begin to nip up the 9 flywheel to pressure plate bolts. If you look in the centre of the flywheel you can just nudge the friction disc till it is close to centred and it will be fine.

    A few things I notice are, you have not fitted the shim washer behind the 6 pressure plate to crank bolts. This is not really anything to worry about I suppose.
    You can take off the large alloy girdle from the engine as that is only there for the 02A box.
    And importantly. There is one dowel missing on the rear of the engine to align the gearbox. The one in the front is there. The missing one may be in the 02A box that came off the engine. It could also be that the 020 box you are about to fit has the dowels stuck in it so you will need to make sure there are only one in each of the two positions.

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    Quote Originally Posted by danster View Post
    A few things I notice are, you have not fitted the shim washer behind the 6 pressure plate to crank bolts. This is not really anything to worry about I suppose.
    Oops, there were none on originally when i took the 02A flywheel off!

    Quote Originally Posted by danster View Post
    And importantly. There is one dowel missing on the rear of the engine to align the gearbox. The one in the front is there. The missing one may be in the 02A box that came off the engine. It could also be that the 020 box you are about to fit has the dowels stuck in it so you will need to make sure there are only one in each of the two positions.
    Do you mean as circled below? Which hole should it be in?


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