Some of you may remember that I posted a request for help in June 2017 for a 2005 TDi 90 that had decided to throw a balancer chain...
Well there's a long story (with a happy ending) that I thought I'd document. Starting with the suggestion to drop the engine through the front on a warm sunny day in July 2017.
... and then admire the thick layer of diesel that had dribbled all over the tandem pump and front corner of the block from the fuel pipes...
... before stripping the turbo for sending off to Turbo Dynamics for refurbish...
... showing the thick layer of carbon deposits throughout the manifolds (both inlet and outlet) that was the result of worn seals.
... before we start on the head by removing the timing chain...
... with essential kit including timing belt locks and M6-M14 spline sockets.
The eventual seizure culprit was uncovered, and the damage was more extensive than originally thought...
... note the eccentric position as the sprocket was relocated around the crank against three flats.
Then the removal became "interesting" with a drill and shear approach to removing the now welded-on sprocket...
... but the cleanup left a suitable home for a second-hand sprocket from WOM Automotive (many thanks Rob!)...
... and a home-made tool using the original crank bolt was fashioned from a hole cutter...
... which slid the 250 degree heated replacement beautifully into it's new home...
... part 2 to follow as I can't add more pictures.
Well there's a long story (with a happy ending) that I thought I'd document. Starting with the suggestion to drop the engine through the front on a warm sunny day in July 2017.
... and then admire the thick layer of diesel that had dribbled all over the tandem pump and front corner of the block from the fuel pipes...
... before stripping the turbo for sending off to Turbo Dynamics for refurbish...
... showing the thick layer of carbon deposits throughout the manifolds (both inlet and outlet) that was the result of worn seals.
... before we start on the head by removing the timing chain...
... with essential kit including timing belt locks and M6-M14 spline sockets.
The eventual seizure culprit was uncovered, and the damage was more extensive than originally thought...
... note the eccentric position as the sprocket was relocated around the crank against three flats.
Then the removal became "interesting" with a drill and shear approach to removing the now welded-on sprocket...
... but the cleanup left a suitable home for a second-hand sprocket from WOM Automotive (many thanks Rob!)...
... and a home-made tool using the original crank bolt was fashioned from a hole cutter...
... which slid the 250 degree heated replacement beautifully into it's new home...
... part 2 to follow as I can't add more pictures.