Camshaft Sprocket

[Alistair E]

Rebuildin the engine and noticed the woodruff key on the camshaft sprocket is showing signs of cracking. Three questions :

How much strain is on the woodruff key or is the bolt enough to hold the sprocket in place?

It's an ABY engine, which other engines use the same sprocket with the hall sensor and same timing setup?

Does anyone have a spare one they want to sell?

Thanks

Alistair

[aelred]

why dont you do something like this?

[Alistair E]

why dont you do something like this?

Aelred

I was thinking along the lines of remaking the key from scratch, making two slots and using a new square. I think you have just suggested a better solution. What would you suggest for the plug, any particular material?

Thanks

Alistair

[aelred]

I just took it to an engineering company and and they did it for me, discussed it a little and hey presto!

[aelred]

the plug is tight fit so it does not come out, the material I am not sure, but anything will be better than the original one

[terrybullwon]

the plug is tight fit so it does not come out, the material I am not sure, but anything will be better than the original one

The woodrough key on my dahlback pulley with is a tommi cnc machined one effectively is shocking..... I am not happy with it one bit.

[Alistair E]

The good thing is, I work for an engineering company. I've just got the pain of having just rebuilt the head and refitted it to the block. Fortunately I haven't tighted the head bolts yet. Hopefully be able to take the whole head in.

Any thoughts on drilling a size, then using the drill shank as the plug.

Alistair

[aelred]

The plug is 6mm but as I say I am not sure of the meterial, 6mm engineering rod?

[Flat on my back]

.

The good thing is, I work for an engineering company. I've just got the pain of having just rebuilt the head and refitted it to the block. Fortunately I haven't tighted the head bolts yet. Hopefully be able to take the whole head in.

Any thoughts on drilling a size, then using the drill shank as the plug.

Alistair

Its not a good idea to fully fit and tighten the cams in, then tighten the head to the block...

Order is head to block, then cams in...well that's the way i would...

[S2central.net]

You need a counterhold for loosening and tightening the cam pulley bolt - lack of which probably killed the key sometime in the past. There is a proper VAG tool for this but its number escapes my brain right now. I bought one from a source in Germany - not huge money either - but easily copied by any decent toolmaker / machine shop.

[terrybullwon]

You need a counterhold for loosening and tightening the cam pulley bolt - lack of which probably killed the key sometime in the past. There is a proper VAG tool for this but its number escapes my brain right now. I bought one from a source in Germany - not huge money either - but easily copied by any decent toolmaker / machine shop.

Whats a counterhold?

[S2central.net]

A dirty big metal bar with prongs that hold the sprocket while you are swinging on the bolt with the other arm.

[terrybullwon]

A dirty big metal bar with prongs that hold the sprocket while you are swinging on the bolt with the other arm.

With you