My relaxed pace CS to 1Y conversion

[keytouch]

Tell us about the bolts that hold the clutch slave on

They're off. With a blooming great breaker bar. After wedging a second spanner underneath.
Did I read somewhere that people weld their nuts on?

[keytouch]

So today I checked the oil filler plug on the gearbox would come out. No problem.
To loosen it off I tipped the gearbox over. When input it back tight way up I noticed a puddle on the floor. Looks like the nose cone gasket, or one of the bolts going through it is leaking.
I think this is part number 091301215A. Can't find on brickwerks but vw heritage has it for 3.90 unfortunately with an estimated postage of 3.95!!!

ImageUploadedByTapatalk1371071707.662836.jpg

Is there much to changing one of these gaskets?

[lloydy]

Do 2WD boxes have the breather on top? if so, when you roll it over oil will fall out

[keytouch]

Haven't noticed a breather
The leak seems to be coming from the top corner nearest to the camera in the wet area on the box

[keytouch]

Right well it's about time I started to make some progress.

Have ordered a low range torque wrench.

Also did a big shop with brickwerks, £270 worth of stuff. And Sod's law dictates the only thing that was out of stock was the spigot shaft bearing.

First step will be to change the cambelt and tensioner in situ in the golf and make sure that is all running smoothly prior to pulling it from the golf and starting the bits swap over.

[keytouch]

Placed the order Wednesday night. Was kind of expecting it today what with the way everyone gets things from brickwerks so quick. No sign of it though. And the stays on the brickwerks website just says "printed". Looks like I won't be doing anything on the van this weekend then.

[keytouch]

The brickwerks order turned up today. So no excuses for delaying really now.

Today I painted the rocker cover, cleaned up the faces and fitted the new rocker cover seal.

[keytouch]

So I'm in the process of changing the timing belt on the new engine whilst its still in the golf.
Have removed the auxiliary drive belt.
Have taken out 4 bolts from the double pulley on the crankshaft, however the back pulley won't come off.
Is it right that I need to remove the crankshaft sprocket bolt to remove the back auxiliary pulley from the engine prior to removing the timing belt lower cover?

[keytouch]

Going to start posting my problems, including the one above in the the mechanical forum as I think it get a wider readership than here. Will keep up progress updates on here though.

[keytouch]

Today I got the waterpump pulley and crankshaft pulley off, with the help of a bloody big hammer and bit of wood. Removed the lower cambelt cover and to my delight none of the seals appear to be leaking so that saves a job.

The next step will be to fit the new cambelt and tensioner. Though I think I need to make a small adjustment to the alignment of the flywheel timing mark and the camshaft locking plate so that they are both just right.

[keytouch]

So following the steps from the vincewaldon website I have now lined up the mark for tdc on the flywheel with tdc positioning on the camshaft.

Having done this the injection pump looks to be one tooth out now and the lioking pin won't quite go in. So when I change the timing belt I just need to rotate a fraction. There is quite a lot of slop in the current cambelt.

[keytouch]

So over 3 hours working on car doing the cambelt change. Get everything finished. Very happy.
Try starting engine. Not so happy. Wheezing and one catch. But no start.

[keytouch]

The engine is at TDC on both the flywheel mark and the no 1 cylinder on camshaft according to cam line positions and locking plate at back. And at this position the peg also fits in the hole of the pump wheel.
So either somehow the actual fuel pump
Timing is well off it fuel is not reaching the right places. I will double check the wire for the fuel cut off, and look to see if there is any kind of priming pump, however I don't think there is

[keytouch]

Finally managed to get her to turn over and start up.

An awful lot of crap coming out of the back, very smokey and tapping noise coming from the engine.

It worked fine previously

[ringo]

Timing is out. Recheck it, that's all you can do.

If its bad its probably out by a notch.

Ringo