My Progress & Timing Question

If you have the proper tool then you're supposed to just tension the belt to it's maximum. I've never seen the tool in the flesh but I'm guessing it can only be turned so far until something stops you being an able to turn it any further. Do you have a picture of the tool? This might shed some light on whether there is some kind of pin or lobe on it that stops it being turned further than it should be.

I need a balance belt pulley....there is a crack in it

Originally Posted by andylossie

I need a balance belt pulley....there is a crack in it

Didn't you get a new one when you got the new cam belt, new balance belt, and new balance belt tensioners?

It is the pulley bolted to the crank, i must of made it worse hitting it with mallet to remove....clipped the edge of it.

Originally Posted by andylossie

It is the pulley bolted to the crank, i must of made it wore hitting it with mallet to remove....clipped the edge of it.

Ooops Dealer only part unfortunately (Alfa Part Number 60620441 - ~£20). You might find somewhere like EB Spares can supply one a bit cheaper. Otherwise try ringing one of the Alfa breakers for a secondhand one.

Spoke to autolusso, very helpfull

GE Help, This pulley is not for coming off it is stuck solid any more hitting it is going to decintagrate. What will i do?

Originally Posted by andylossie

GE Help, This pulley is not for coming off it is stuck solid any more hitting it is going to decintagrate. What will i do?

You did remove the 2 silver ribe-headed bolts didn't you?

Can be seen in the picture of the following post...

Balance Belt Crank Pulley

Yes i removed the 2 bolts. its stuck solid.I have been tapping round the full pulley and nothing.

Here is the buggar. Tried everything from hitting it to talking to it

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I don't know why your pulley isn't coming off because mine almost fell off itself once the bolts were out. The back face of the balance belt pulley and the front face of the cam belt pulley behind it simply mate together with a small shallow dowel to ensure correct location/orientation. It shouldn't be stuck on that hard unless someone has glued or welded it in place

I would try some localised heat from a blowtorch to try expand the pulley which will help to break any adhesion (corrosion or glue) that may be between the mating faces.

The following post shows a picture of what is behind the balance belt crank pulley once it's off...

Cam Belt Crankhaft Pulley

If you look at the 7 o'clock position on the cam belt crank pulley you will see the small locating dowel that ensures correct location/orientation of the balance belt pulley.

Thanks forall your help from the start i really do appreciate it.

I tried a large lever behind it, so i was levering & hammering at the same time and still nothing. What if i take the bolt out in the middle and remove both the t/belt crank pulley and the b/belt pulley and inspect from there. Would that work. I would need a thin socket by the looks of it.

Originally Posted by andylossie

I tried a large lever behind it, so i was levering & hammering at the same time and still nothing. What if i take the bolt out in the middle and remove both the t/belt crank pulley and the b/belt pulley and inspect from there. Would that work. I would need a thin socket by the looks of it.

I wouldn't even attempt to remove that bolt unless you have no other available option. That bolt goes directly into the end of the crankshaft and is done up to ~360Nm of torque so getting it out is very difficult without first locking the flywheel otherwise the crank will just turn with the force you need to use on the bolt. Then tightening it back up again to the correct torque poses a problem because DIY torque wrenches can't handle anywhere near that sort of torque. You need a professional torque wrench and ones that can handle that sort of torque cost >= £100

I would try the localised heat option I suggested first and see how that goes.

Heat did not work.

With damaged threads on the idler plate and this i think the previous mechanic needs shot

I am going to fabricate a bracket that will bolt to the pulley with a large bolt in the centre to tighten thus pulling the B/belt pulley in the oppsoite direction, if you know what i mean.

Originally Posted by andylossie

Heat did not work.

With damaged threads on the idler plate and this i think the previous mechanic needs shot

It does sound like the previous belt change was well and truly bodged

There is definately something amiss because there is no way that pulley shouldn't just fall off with the two bolts removed and a small amount of gentle coaxing. There is clearly something holding it it place which shouldn't be there

Originally Posted by andylossie

I am going to fabricate a bracket that will bolt to the pulley with a large bolt in the centre to tighten thus pulling the B/belt pulley in the oppsoite direction, if you know what i mean.

Yep...like a bearing puller. I was going to suggest one of those as another possible option but if you have the means to fabricate something similar yourself then it will obviously save on the cost of having to go and buy one.

Finally she gave in

Used a slide hammer taken more than 5 hits to get it off (i have had more bother with this, than a siezed old brake drum i removed from a ford), however there was some sort of adhesive on the face as it decided to take part of the crank pulley with it (on the edge) turned the b/belt pulley round and seen the missing bit stuck to the b/belt pulley. I dont think it will effect the belt, just a bit concerned as it has a sharp edge. I might file it down, i think the new b/belt tensioner will keep the belt in place.....tell me what you think.

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I have never in my life seen such a bodged job of a cambelt change, i am shocked and for reference the b/belt pulleyhad a crack in it prior to me hitting it, with all the force required the weak bit gave in. I will get there in the end

I think i can see what the last owner has done, because i would not imagine a mechanic doing such a thing.

It appears that he has tightened the b/belt pulley and injected some araldite at the back I think the crack on the `1st pulley was due to him hammering on. as a result i have the lip cracked off the crank pulley because of the bond between the pulleys. The crack was small on the b/belt pulley,but gave in when i was trying to hammer it off. i was not bothered though as it needed replaced anyway.

Anyway thanks for all the help GE....will need to send you bottle of whisky

Hmmm...that cam belt crank pulley doesn't look good. I'm not sure what I would do about it to be honest. Complete replacement would be the best option but then you have to deal with getting that bolt out and back in again as previously mentioned.

You should certainly file/grind any sharp or rough edges off but I'm not sure if there would still be a chance that the belt could get caught up on that lip as it's going round.

Might be worth speaking to smaky when he's back and seeing if he has the special tool to lock the flywheel and a meaty torque wrench that can handle >= 360Nm. If he does then I would recommend just replacing that pulley completely and borrowing the tools from him, or better still getting him to actually help you do it.



P.S. I'll drop by and pick up the whiskey when I'm next up in Scotland...half my relatives live in Aberdeen

Ouch. I still have the bit that snapped of,maybe a chance of using extra strong loctite-super steel epoxy. Even then I think the balance of the pulley will be out.

Originally Posted by GialloEvo94

P.S. I'll drop by and pick up the whiskey when I'm next up in Scotland...half my relatives live in Aberdeen

Anytime, visit scotland on the next AO Run

Think i will try the epoxy, tried it on other steel and had to hammer it off again so it's more than strong enough. Looking at the marks on the pulley the belt does not come into contact with the side so i may get away with. With regards to the balance of the puley i dont think it will be that bad with a small bit of resin holding it.

You've had more than you're share of bad luck with this belt change, it's a shame the monkey before you wasn't the one to suffer doing it a second time around. <