New Member.... Some help pls.... ;)

Chief · Post by **Chief** » Wed Mar 03, 2004 2:30 pm

Hi Guys,

My fiance has a 1991 VW Polo Coupe (AAV Engine) 1.3. Damn head gasket has gone for the second time in about 40k miles

I decided to do the job myself this time, cant afford to give Â£300 or odd to the garage...

Anyway, I have stripped down to the camshaft, but I cant release the camshaft sprocket to remove the camshaft. The camshaft sprocket does'nt have any holding points on it for a tool, so I have been wedging a screwdriver through one of the holes in the sprocket into that screw hole behind which is to keep the plastic cover in place. HOWEVER! I have now snapped two screwdrivers and snapped the plastic cover where the hole is where it slipped

. Seeing as you guys are the experts on this engine can someone give me some ideas or suggestions on how to do this please? Or a link to a walkthrough guide would be great! haynes book of lies is useless (as you probably know already!!!)

Just so you know, I have done the following....

Drained Oil (I know now, that I didnt have to.... damn haynes

)
Drained coolant
Disconnected coolant hoses
Removed air filter
Removed TB
Removed all leads and dizzy cap
removed camshaft cover

Think thats about it... thanks for your help!

Rick

amstrange1 · Post by **amstrange1** » Wed Mar 03, 2004 3:20 pm

I wedged an allen key into the crank pulley against the engine mount bracket bit. Make sure it's a thick allen key though...

Alternatively you could use a long 10mm socket on the timing belt cover bolt near the crank pulley - but I couldn't get this to work very easily.

hardhitter · Post by **hardhitter** » Wed Mar 03, 2004 6:28 pm

OK, heres how to hold the camshaft sprocket to stop it turning.
You need a deep drive 10mm socket (6 point) and a medium extension on a 3/8" drive. You also need the correct size socket for the sprocket (24mm I think) with a long breaker bar to undo it, because it will be tight.

The trick is to push the 10mm socket with ext through the sprocket onto the 10mm bolt head behind it, with the sprocket in the right place. This will need holding firmly while you undo the big bolt. You have to be careful so it doesnt slip off too.

Thats how I always do it, and it works for me. Others may have different ideas.

You have to be very careful indeed, if you were to hold the crank pulley and try to undo the cam sprocket. It puts a lot of tension on the timing belt, which could slip a tooth.

HTH

amstrange1 · Post by **amstrange1** » Wed Mar 03, 2004 6:40 pm

That's a way better explanation than I managed Dan! I used the allen key way because it was easier for me - I think putting the sprocket back on will require the 10mm socket approach though.

Chief · Post by **Chief** » Wed Mar 03, 2004 9:09 pm

Ah ha! This makes sense

Just need to try and get that screw back in again and hope I have'nt damaged the thread with my screwdrivers...

Cheers

Chief · Post by **Chief** » Wed Mar 24, 2004 12:29 pm

Me again

lol.... Not worked on this polo for a while.... got bored

Ok... I got the camshaft sprocket off head is out, not cracked

I am going to be changing the cambelt at the same time... but...

The 4 allen bolts are off and the pulley is loose, but I cant get it over the crankshaft bolt because of the side wall of the car is too close.... Any ideas? Or is it just a case of brute force and a lot of pulling and pushing?

Cheers guys

Rick

hardhitter · Post by **hardhitter** » Wed Mar 24, 2004 6:20 pm

yes the pulley is too close to the inner wing to get it off the crankshaft. you need to drop the engine and it will come off.

optima21 · Post by **optima21** » Thu Mar 25, 2004 6:53 am

Yeah its too tight to get the pulley out, but all I did was undo the engine mountings and lever the engine away from the inner wing with a peice of wood.