Fremder

I'm so frustrated and sad!!!
last night I had no idea how to turn the crank and found a write-up regarding TB job on 2.8 30v.
It said "loosen accessory pully before turning crank shaft". so I loosened the pully and tried to turn the crank, it was so hard to turn and all of sudden the accessory pully I loosened popped out and it broke the lower TB cover..
I guess I loosened the pulley too much, it's 100% my fault...

The entire TB was loosened and off the pully. I tried to put the accessory pully back on but the tensioner pin was pushed out and the pin block the spot where pully should be pushed in.

Most serious situation is both cam shafts were turned itself due to there's no tension on the belt. it's entirely f**ked up.

below is the current status in the car.
<img src="http://i169.photobucket.com/albums/u203/edge71/A4%20Timing%20belt%20replacement/DSC05460.jpg">

tensioner (arrow) pin was pushed out when accessory pulley(circle) was popped out.
<img src="http://i169.photobucket.com/albums/u203/edge71/A4%20Timing%20belt%20replacement/DSC05461-1.jpg">

I can put the pulley back in there, but not able to push it all the way back in.
<img src="http://i169.photobucket.com/albums/u203/edge71/A4%20Timing%20belt%20replacement/DSC05464.jpg">

hope you can understand what's going on my car. is there any way to fix it up? how can I LINE UP TDC MARK AND CAMSHAFTS?

thanks in advance!!!

Kris Hansen

then insert a suitably small metal pin to hold it closed.

Why did you attempt this without the proper cam holder tool? It exists for a reason. That is, to line up the cams, and keep them in place while you are changing the belt.

You can line the pulley up by putting the lower plastic bits back on, and matching the line on the big pulley up with the arrow. This is not EXACT though, best to use the hole for the crank pin.

Why did you feel the need to turn the crank with the belt off? With ANY ENGINE, not just this one, you ALWAYS set it to TDC before removing the cam belt..

qfrog Ti20

Do you have a cam lock bar?

Fremder

i have rented tool kits from BLAU, so yes I have all the tools needed.

qfrog Ti20

If you don't have the tools you need to buy them.<ul><li><a href="http://zdmak.com/wbstore/main.asp?action=PROD&amp;PROD=VW3391X3242&amp;CTMP =1&amp;LowCt=0">http://zdmak.com/wbstore/main.asp?action=PROD&amp;PROD=VW3391X3242&amp;CTMP =1&amp;LowCt=0</a</li></ul>

qfrog Ti20

Without the belt in place the cam bar should be in place. Either your guide for this job is ****ty or you are not following the directions very well, or a combination of the two.

Kris Hansen

Well, you CAN take it off once you get it all at TDC...

Fremder

as you said i'm gonna remove tensioner with TB off. at this point do i have to put cam bar on cam shaft? anyway i don't think I can do that because cam shafts are not lined up.

1. remove tensioner, and I have new tensioner which is already compressed by pin.
2. install accessory pulley and try to put timing belt back on. it's gonna be pita i guess.
3. turn the crank, while still pin's there. try to line up tdc mark and cam shaft big hold inside.
4. if everything works out, place cam bar. then follow the rest of preocedure.

will it work out?

Fremder

it just didn't work out. I thought I should line up tdc first and then place a cam bar. am I wrong?
anyway I tried to turn crank without cam bar and with one of the pulley loosened. The problem is here. I think I loosened the pulley too much.

Kris Hansen

if the crank is at TDC, you should be able to line the cams up by CAREFULLY turning them SLOWLY....