(12-06-2015, 01:21 PM)pug306driver Wrote: hi dudes,
 Just doing this job very soon..........pic is of the belt the car came with and still shows some memory even after been contained within the replacement belt wrapper sleeve in the back of the car, lots of heat cycles due to warm weather.





This belt ( dayco ) seemed to touch the spring tensioner allan bolt and squeak.

The new belt was fitted ( Unipart ) and of cause did the same thing, touched the allan bolt and squeaked.

After some time it was found to have "skipped" over a ridge outwards on the crank pulley, due to "misalignment" and all that flapping about on the a/c to crank pulley run. This caused lots of noise from the spring auto adjuster when cold but was not tooo noisy when hot.

The crank pulley that came with the car is shown with the Unipart belt fitted, with the auto adjust as it should be ( the holes align up for the locking pin tool ) and with the manual adjust jockey wheel showing some tightening adjustment left ( eccentric ).



The crank pulley measures 148mm diameter on this face, I cant get to the rear face to measure diameter there. Gates info says it should be 161mm diameter at the back. The crank pulley is the same diameter across the drive face @ 148mm with no increase in diameter at the rear. I have also noticed an chunk missing from the rear "peak", probably broken off when the bod who did the cam belt hit the pulley with a hammer??. This will encourage belt squeak and flapping about  I would have  though??

Some cast in numbers are visible on this pulley so I hope someone can identify it please. The numbers on the rubber by the white marks shows 3553236....then a 17.  I will be back tomorrow with the cast in pulley numbers.....





number stamped on outer metal ring : 92400
number cast in oblong on inner hub  : 2207?     maybe 22C7??
number cast on  inner hub : C15431 LS 2

The rubber vibration  damper is seen to be sticking out somewhat ( and at the rear of the pulley ) and is cracking. There is not much clearance at the back of the pulley and I suspect the rubber at the rear has been rubbing on the cam belt cover.

 The Gates data and fault pics say this  pulley in need of renewal.

I have been trying to source a Lynx pulley but can get a Gates one locally. They make the belts etc so should be a reliable make.

I intend to try the "TOM" run at first in de air conning, and hope that there is no alternator slippage, but utilize the manual adjust jockey wheel to control any flapping about due to the divided "long" belt run.

Hopefully the crank pulley bolt will co operate and come out with no snags.

The gate list TVD1002 crank pulley as being correct, 161mm diameter at the back....add an A for the one with a new bolt, and a 1750 belt  for the standard fitting crank pulley( with a/c ) .

If the crank pulley in tom's pic is standard diameter ( 161mm ) then the belt will be 6pk1185.



Please TOM could you confirm that the crank pulley in your pic is standard diameter of 161mm please??

the crank pulley in the pic above looks similar to the one on our car but is not identical....

so an interesting sunday morning.....

Thankfully the crank pulley bolt came out ok, was a bit worried at first but all the threads look ok.

The pulley cam off quite easily, some lube and a cuppa then gentle pursuation, wobbling bit by bit and lub then tap back home, it came off hassle free.

The timing belt looks ok but will make a distance piece so the crank can be rotated exposing the cam belt bit by bit, to be sure.

The crank pulley is the same diameter across the "drive face" and the missing chunk looks well polished!

There is evidence of the crank pulley "rubber" on the pulley inner face having worn a circular groove in the cam cover, but not tooo deep.  pics to follow...

the pic of the pulley in the Haynes manual for a 2l hdi shows a different cast on number to the pulley that has come off, and the gates info says the proper pulley is a different diamenter, so this engine may have had the wrong pulley fitted??

so, when measured on the bench, the dia was found to be 151mm across the drive width.

you can just make out the missing chunk at about 5 o clock.




wear groove and some melted plastic of the  cam belt cover......will have a go at removing the lower cam belt cover for better look and inspection.....