Nope wouldn't have thought so, it's never been off so can't see that being an issue. Had a search about but can't find anyone else with a problem. Hoping the tensioner stud is the issue but the mechanic can't see it, as when you tighten it up, it would straighten and flatten it against the head! VEry confusing.....
yeah there is two timing marks on the wheel - one on each side one aligns to rocker cover marker. other mark on back of the wheel aligns to top of head as far as i remember. (basing this on KR 16v) tis a strange one your experiencing
Right will ask mechanic to check but going to think it wouldn't be that but good suggestion! Real taxing one. Tomorrow new stud will be fitted, put in a drill bit and two different drills we could see it was not straight. So hoping thats the issue but mechnic not so sure given that the tensioner bolts directly tot eh side of the head and pulls itself in. When cranking you can start to see the belt coming off from the tensioner to the upper pulley as it then starts to move round coming off by 3mm as it moved round the other pulleys! That makes me think it HAS to be the tensioner /stud at fault!
i know for a fact that if you put it on back to front it will sit offset from the belt. also, you say you have a green mark on your wheel? on KR pulley they are notches, no paint. so id just double check incase previous owner had put new timing mark on it. though you'd see the original notch also in the pulley either that or hope the stud fixes it!
Thanks Gambit really helpful! Will update the theread tomorrow when Dave does further work on it for me
Right then, so yesterday was tense, new stud fitted and EXACTLY the same problem I am afraid! Doh! Not really sure what else we could do. Have posted some pics so you can see how far off the cam belt is. We think that possibly the belt does just sit at this point.......We ran the car for some time with all the belt cover off etc and it won't fall off as the tensioner keeps it on. We checked all the pulleys for allignment and they are all straight as a whistle. The only thing we can possibly see is that the cam belt cover is slightly warped.....and this has warped in and started to rub which is then causing the noise of course. Check the pics and see what you think. Have spaced out the cover slightly with a washer and all is fine now!
At the point I took the photos it wasn't timed up properly. We checked about being back to front and the markings on the outside and inside of the pulley lined up perfectly. Can't see how the pulley has ever been off either, checked service history and never had any cambelt work!
looking at the top pic the belt appears to come near back into line when running off the top pulley and onto the tensioner? so that would say its further down towards the intermediate shaft that is causing the belt to sit out. might be an idea to replace the end cap/seal on the intermediate shaft. dont think its too expensive from VW. and get 2 new upper & lower belt covers.
yeah think i will get two new covers, can't be expensive. Any one got the part numbers at all off EKTA for it? 16v ABF 1996? No worries if not, will pop to VW and order. Can the end cap be replaced easily? and what effect would that have.... Cheers for all your help mate.
yeah you can replace end cap/seal easy enough. just need remove pulley of shaft and then withdraw end cap, stick on new one - just two bolts hold it. no need to remove actual shaft. it should take up any in/out play in the shaft give rubjonny a PM for the part nums
ahhh is that the same for the bottom pulley as well. I thought the whole shaft had to come out which would be the whole engine out to be able to get to it! I guess the end cap have the bearings in it?
nah the bearing shells are pressed into the block itself. its just retaining cap & seal bottom pulley is just 4 allen key bolts to remove in order to get bottom cover off - dont need to touch centre crank pulley bolt
So really I need to get Rubjonny to get me part numbers for the following: top cam belt cover bottom cam belt cover and 1 set of cap and seal for intermediate pulley? Thanks mate.
yep ask him nicely and he'll give you a wee exploded diagram showing you all you need for intermediate shaft retaining cap/seal/bolts id also get 4 new bottom pulley bolts also if you round a few getting the off
Have sent him a polite message Then to get the mechanic to fit them again. I guess you can't get a set of cap and seals for the lower pulley presumably as well?
nah thats the main crank pulley & crankshaft oil seal, and i wouldnt be touching that unless its actually leaking your just taking of the bottom aux pulley which is bolted to main crank pulley
O - top pulley O - tensioner O - Intermediate Pulley O - Main Crank Pulley (Lower Pulley) That how it looks, have I missed out a pulley? Sorry to be so dense! : (
