oh sh@t I've got a rattle

[Martynf]

I started her up tonight, started on the button, no leaks anywhere, but... theres a rattle from her somewhere.

Must admit I'm cra@@@ng myself a little here. I think it sounds like the new water pump maybe. The noise sounds like an external rattle, it increases with engine speed, but does sound like the rattle is external. The thing is too hot to touch currently, so I'll have to wait until the morning.

Anyone had a water pump expire, what did it sound like?

Martyn

[Mikes2]

If it's a whirring type sound, it's possible the belt is too tight. You should be able to twist the belt 90 degrees by hand

[Martynf]

Thanks Mike,

It was def. a rattle sounding like its coming from the water pump area. Hard to tell really, so I stripped her out again and it was the timing belt cover??? it was fitted right, but the PS belt was rubbing on the bottom edge of it causing the rattle. Thing is... its a new cam belt cover fitted? I looked at the old one, that had also been rubbing during its life, to the extent that the cam belt cover had been worn through a fair bit. The new cover is doing the same??

The belt is tight enough, just cannot turn the belt by 90 degreees along the longest run. There isn't any adjustment on this, I mean, you cannot space out the crank pulley! there isn't any shims on the PS pump pulley, so I cannot adjust anything to stop it rubbing???

There is a slot on the bottom edge of the cover, that is engaged perfectly with the metal bottom pulley cover, so what gives? how can I stop the PS belt from rubbing on the cambelt cover?

I removed the cover and ran the engine, no rattle as before, so this is the cause of the rattle I could hear. Although... now I can hear a different internal metal rattle!!!!!!!

NOW.... I don't know if that rattle was there before the top hose went and lost its water, I mean its not often you have the front of the car off, timing belt cover off and stick your ear to the front of the engine. This is an internal rattle for sure, nothing drastic, could be quite normal, but I've nothing to compare it too...

Anyone near the Dartford area fancy stopping off for a few minutes nearby, so I can compare????

Martyn

[s2avant]

Martyn,

Mine had exactly the same rattling caused by the PAS belt on the cam belt cover. It must be those spurious 'german sourced' parts your supplying Only joking. On a serious note we gave mine a quick spray with some lube and all was quiet and has been since. Apart from the alternator belt tensioner that fell to pieces.

I'm not sure whether it has just rubbed it's way through the sticking point or not but I've had no more problems with it.

Ben

[Martynf]

Thanks BEN! Spurious indeed...! they ARE NOT spurious!! they are not that good!!! mind, mine are better quality than the crap your dealer chucks out

Sounds like another 'feature' of the S2 then? maybe I'll put the old cambelt cover back on as that one had been completely rubbed through by the PS belt and didn't rattle at all!! this engine rattle has got me a little concerned though... me thinks I'll spend a little more time this weekend tracking it down. Might as well whilst she's apart.

The new rad, stat, pump and hoses seems to of made a nice difference to the water temp though! it runs cooler now and the fan runs for less time when it comes on, IE cooling more efficiently now :-)

The PS belt rubbing and rattle was caused by a small 'dent' in the lower crank pulley cover which I hadn't spotted! its only a small indentation. I guess when I ran the engine up the cambelt cover 'popped' off the lower cover! That's been straightened out and now the PS belt doesn't rub any more :-) joy! that's one more problem sorted :-))


Thanks Ben!
Martyn

[Martynf]

Well this new wierd rattle of mine turns out to be the shaft of the power steering pump! you can get hold of the PS pump pully and pull it forward and backwards by about 4-5 mm

If anyone gets an odd rattle from the front of the engine, check your ps pump for shaft movement. Only solution = replacement

Martyn

[S2central.net]

Ouch !

You gonna make it on Saturday then ?????


Paul

[Martynf]

Certainly am Paul!!

A very nice man has a power steering pump which will be winging its way to me soon :-)

I'll drive up Saturday on the noisy ps pump, the worse that can happen is that the pump gets completely shot on the trip and lets face it, its gone already! so I cannnot damage it any more than it currently is!

The AA membership is up to date, and I'm getting to know all the breakdown guys by name now!

I have to make it this Saturday as I've an appointment with a certain Guru to swap over some natty electonics! as long as the car makes it there, I can have it recovered back if the worst happens. I'll see you there.

I can only guess that maybe the PS belt had been over-tightened for a long period of its life which has cuased this damage? or just plain unlucky....

Anyhow, that's S2 ownership, I knew what I was in for when I bought her. I just hope the expenses stay away for a little while. Need to recover from the current bout of expenses (repay the CC)

See you Saturday Paul.
Martyn

[S2central.net]

Aye - no worries on swapping your ECU back in. Only thing I have to do is graft the stock chip stickers onto your homefries to complete the stock appearance. Picky or what ?

Only thing to concern me with a hands-on approach on Saturday is the little-un who will only be safe and happy if he is sitting in the driving seat whilst I root around under your glovebox. I promise he won't spill anything

See you then if all goes to plan... Are you aiming for any particular time on Sat ?


Paul

[Martynf]

10/10 for attention to detail thank you. Little un is more than welcome to play racing car driver :-)

I aim to leave Kent about 8.30-9AM It *should* only take me 2 hours to reach Junction 14 of the M1. Worse case arrival time should be midday.

Thanks Paul
Martyn

[PeterS]

Guys/Gents/any Ladies?

There are a couple of things to keep in mind when replacing the timing belt...Too tight,, and you will get what we affectionately call the "turkey warble" too loose and the distributor drive noise on a 3B will become more pronounced.

The bentley manual and audi state that the installed belt should be tensioned to the point where it can be twisted 90 degrees when held between thumb and fore finger. (talk about being open to interpretation - are your thumb and fore finger calibrated?)

Another thing to be careful about on the 3B is not to bend the timing belt shield against the engine block when removing or installing the water pump. what can happen is that the bent shield contacting the Cam gear... To avoid this I typically double nut the upper cam cover mounting stud and remove it( it goes throught the shield into the block. The lower mounting stud is pressed into the shield and can be left alone. Doing this ensures that the rear shield will not get bent and that the upper plastic timing belt cover fill again fit snugly after reassembly.

-Peter

[Martynf]

Good advice Peter!

I checked the timing belt whilst replacing the water pump and I did nip her up a little. I can now just turn her though 90 degrees on its longest run between any two points. I calibrated my fingers first using a 5lb hammer :-)

My lower pulley cover was slightly dented in which is why the timing belt cover popped off of the PS belt rubbed on it at the bottom, sound familiar? that was carefully straightened and now the upper plastic cover is a good snug fit over the lower cover.

I do believe that the ABY water pump / covers are easier to work with over the 3B's, how you described the covers on the 3B seems to be quite different to the ABY set up.

Thanks for sharing your knowledge on this Peter
Martyn

[Vagsport]

Paul, what are you like with RS4 ECU's? Got any custom maps for these yet? Heard good stuff about your home fries, specially from Martyn.

[S2central.net]

Siena - sorry I don't have any insight at all on the RS4 chips, but I do know a man with some contacts who can maybe help you. You might have seen some of Mihnea's posts on this board already - his ECU knowledge is wider than my I5 20V Turbo chippery. Check in with him on the RS4 situation !

I'm pretty sure that the RS4 can be reprogrammed via an interface cable - obliviating the need to rip out the ECU and get down with chip sockets etc.

PS - I'd love to hear back from you on my question about the AEL block and all that good stuff. That's something I would be seriously interested in building and chipping.

Cheers,

Paul