Corrado 1.8 16v KR cambelt change, checking all timing.

[lloyd88 10]

Hi guys, got a few questions please.

 

1st: i noticed that the woodruff key is snapped on the camshaft pulley, do you think i should replace the pulley? or is it friction that keeps it there

 

2nd: what socket is used to get the crank bolt off?

 

3rd: the research ive seen tells me the flywheel mark should be an 0 at tdc but what im seeing is just a |(line) is this correct?

 

thank you!

[davidwort 0]

1. yep, replace the pulley

2. you don't need to remove the crank bolt to do the timing belt on a 16v although the outer damped aux pulley may appear to be part of the crank pulley it's not, it just seizes a bit in place

3. line up the crank pulley with the timing cover arrow, this is TDC, and the crank mark should be aligned, there is a TDC mark and a 6 degrees advance mark on the flywheel

[lloyd88 10]

thanks fro the reply.

 

i know i dont need to take the crank pulley off but i want to inspect it and replace it with a new one and bolt (ill explain later)

[Wullie 1]

Had a similar thing happen. Whole saga here, mainly post 14 which has part numbers and prices at the time. http://direct.the-corrado.net/showthread.php?t=55045&page=2

[lloyd88 10]

dont think mine has slipped but a garage did the most aweful thing a few years back to my rado and im sick of the pinking etc so im starting from scratch. anyway i have found the 0 lol

 

it looks more like this though so sweet! and its at tdc

 

[ATTACH=CONFIG]78448[/ATTACH]

[lloyd88 10]

got the pulley off, using the starter...

 

luckily the crank slot is in great condition but will need new pulley as slot is bad

 

p.s thanks for the numbers i found your post through google already :)

 

[ATTACH=CONFIG]78449[/ATTACH]

[ATTACH=CONFIG]78450[/ATTACH]

[lloyd88 10]

anyone have a spare camshaft gear? im dreading asking vw

[lloyd88 10]

ordered new

 

crank pulley, bolt and cam pulley

 

not bad price tbh, crank pulley £15 by febi, bolt £5 and cam pulley £30 by vw

[lloyd88 10]

anyone know the correct torque for the bolt?

[davidwort 0]

taken from Haynes manual for KR/9a Passat -

camshaft sprocket bolt 65Nm

crank pulley bolt, 2 types:

hexagon head 180Nm

12pt stretch bolt 90Nm, turn 180deg, 65Nm

[lloyd88 10]

12pt, thank you.

 

cleaned up some of my wiring whilst i wait for my new bits, couple of days...

 

heres a quick pic of my rado that i will be selling soon :(

 

[ATTACH=CONFIG]78458[/ATTACH]

[ATTACH=CONFIG]78459[/ATTACH]

[lloyd88 10]

whats with the added 65nm on the crank bolt? or am i just being stupid

Edited April 30, 2014 by lloyd88

[davidwort 0]

could be a Haynes error/misprint as for comparison the G60 Bentley manual states 80Nm (six point) or 90Nm plus 180 degrees for the twelve point.

 

No, apologies, I misread the torque settings table!

Haynes is definitely 90Nm + 180 degrees, same as G60 settings from Bentley

camshaft is 65Nm (Haynes), 80Nm on the 8v G60 (Bentley), a bit odd as the 8v sprocket is narrower ???

 

there is a big mismatch in the non-stretch 6 point crank pulley bolt values though 180Nm(133lbft) Haynes, and only 80Nm(59ftlb) in Bentley, not sure what is going on there, I know most crank pulley bolts are about the tightest bolts on any car though, most need a special bracing tool and breaker bar to remove, or a mega-torquey electric hammer gun!

Edited April 30, 2014 by davidwort

[lloyd88 10]

thanks, just having a hard time keeping it all lined up while tensioning the belt

[davidwort 0]

I've put a spanner on the cam pulley before to turn it against the pressure from the valve gear to line it up, then turn it over once and check all the marks, see if if needs to be moved a tooth either way

[lloyd88 10]

NEED HELP QUICKLY PLEASE

 

ok so with all other marks perfect, im having this problem again where the cam dots wont line up perfect

 

flywheel/crank marks all correct and cam/cover all correct:scratch:

 

[ATTACH=CONFIG]78479[/ATTACH]

[lloyd88 10]

lined up cams and im ignoring the cam cover mark, out by a little but now cant get the crank to line up because everytime i tension the belt it moves, even moving it back a tooth doesnt work......... had enough today.

 

maybe im applying to much tension? dont think so due to me being able to turn it 90 with little effort

Edited May 3, 2014 by lloyd88