Simple job gone wrong(cambelt on scirocco GTII)

before some onew thinks i am a complete idiot I have done countless belts before and worked as a mechanic 10yrs ago and still work in the motor trade. I do all my own work from engine building to spraying and about did the head on my 2.0td MG which runs 2 timing belts after the cambelt snapped before its intervall . I just wanted to do the belt befrore pressing the rocco in as my dailey driver as I have my headgasket to do on my 1.4 diesel 106.

So how can a 1/1.5 hour job go wrong? heres how;


right went to do the timing belt on the gt11. the bottom pulley was seized to the sprocket so rather than knacker the pulley as its a bit thin and rusty I decieded to pull the sprocket off to drift the pulley of with out damaging it.

This is where its gone horribly Pete Tong.

The bottom bolt I know is tighted by Hans at the factory to FT and then some. so I chocked it all up and got the big bar on, this didnt go as planned. the clutch slipped and threw my timing out.(not so much of an issue yet).

The bugger came off so off to the kettle for a brew i pulled the sprocket/pulley assembley off and worked the tin pulley off. It was at this point I noticed the keyway on the sprockey had sheared. Buggeration.

I have a new sproket of the same part number from Tps I have fitted this and the spacing of the bottom pulley to the water pump is now out. the alt and water pump are fine

I dont know if it was out before as i didnt check I just pulled the belt off. So heres my questions:

1) should the water pump pulley have a spacer behind it or are there difrent bottom pulleys?

2) can some one tell me where all the factory marks are as I will have to static time the whole thing from scratch rahjer than relying on my paint marks.

3) Why do simnple jobs just drive you to drink?




PS its not all in vain the belts showing signs of micro cracking and the tensioner has more play than a 8wk old spaniel

Sounds like a typical professional mechanic.

I've never heard of a crank pulley being seized. Its bolts, sure, but not the pulley itself. A pulley puller has always worked for me.

I did the car on the drive with no real gear apart from a spanner roll and socket set.

the pulley was stuck on the sprocket as it looks like its never been apart. as they are only thin bits of tin I didnt fancy knocking a chisel behind it to walk it off the lip it sits on.

This is why I thought I would pull the sprocket off so i coult get right up to the lip it was seized on and not distort the bottom pulley.

Not having a Impact wrench undoing the 19mm double hex headed bolt with a strong arm caused me the bother as when the bolt finaly moved the drag from the big flat face dragged the sproket round shearing the woodruff key in the crank.

Cheers for the help btw.

Right Its done

The pulley I got of a lad on the rocco register has sorted the alignment out issues.

I have had the dizzy out and reinstalled that the right way round the roter arm was about 120degrees out. This has then brought the timing marks right on the pulley and intermidate shaft right. I have also move plug leads round to match the correct dizzy position

The intermediate and pully dots line up it starts and runs like a goodun now all I need to do is strobe the timing and sort the carb out properly as its jetted wrong.

Would say thanks for the help but. :dontknow: