Fright of my life, what to do?

[URquattroGus]

Well, today, 1 week before mapping I was sorting out a few small bits and checking the car over. I went for a short test drive with no problems, however, when I got back and parked up I noticed a loud knoking sound!

I started to presume the worst, engine rebuilt here I come, but I tried to keep a cool head.

It turns out it was the front pulley and cambelt cover interfering, inside and outside of the cover by the looks of it, just as well this didnt go on for too long;

Pictures:











So obviously it looks like I need a new cover, front and back.

The rear one is starting to split by the roughed up area, and this means the front section will not say back either.

I loosened the fixings, but predciatble there is no way of getting the rear cover off without taking the cam belt off, or even the pulley too?

Does anyone know???

I have never taken off or fitted a cam belt before, is there are easy way? Can I just mark the belt or do I need a locking tool, also how do I get the belt tension right?

Really need to get this sorted before next sunday when car is going to be mapped again.

Going to look up the part nos now. Presumably it plain dangerous running without a gaurd?

[djh]

was it a 3b or aby? if aby the cover is NLA now.

[URquattroGus]

It's an AAN.

Maybe I could "Plastic weld" the back bit?

[djh]

bit easier to source as people do break them more often than whole aby's. Could try audi about one?

[URquattroGus]

The AAN belt cover looks different to what I have (there is no oval top on mine), but I do have a 7A Cam cover fitted...

Or are the parts pictures not accurate?

[UrS4boy]

The first thing is to figure out WHY the belt / pulley has contacted the belt cover(s). Problem with the cover installation or problem with a belt or out of alignment pulley?

[URquattroGus]

Its just a cover issue really. If you push the cover in it stopped the noise. Belt alingment (both cam and services) seem fine.

There is minimal clearance between the serpentine belt top pulley and the gaurd.

There was a wire from the cam position sensor that was not routed very well for one thing.

Have used a soldering iron to try and fix a small crack. For now it's back together with no interferance.

We will see.

How easy is it to take the cam belt off to change the rear gaurd if I want to replace it?

[DJones]

It's not hard at all, the worst part is removing the front bumper and valance so you can get to the crank bolt... Get the parts pop over one Saturday and I will do it with you..

[Sleeper_Avant]

its just a case of getting the pulley off and torqued back up, ideally you need a crank locking tool, or you could air gun it back in place (not reccomended but works)

ive got an AAN outer cover here too, cant say what condition its in as ive nt seen it for about a year but should be ok as it came off my A4 when i couldnt close the bonnet lol

i could bring the cover to you and have a look at your motor during the day wednesday if you want?

i would cable tie the belt to the top pulley and take it off that way, can sort it out if you wanted again on wednesday.

let me know where the car is (i know your sort of local to me, havent got anything booked wednesday yet so can make time if needed.)

Sean

[URquattroGus]

Darren, Sean, thankyou very much for the offer, I really appreciate it.

I may have to take you upn on it a later date, but for now I have ordered a new front cover for tomorrow for just £20 and I am confident that the rear guard will not contact again.

I am working every day this week inc Saturday and I just don't have the time to take the belt off and replace the rear guard just yet.

I can't get one anyway, I took the part number off the rear section and it was 054109145D

When I rang my local audi dealer they said this was not a good number, but it looks there or thereabouts to me, and a google search nrings up some info.

Would anyone be able to check this part no?

Sean-maybe we can meet up sometime once my car is mapped and you can have a proper look?

I

[Sleeper_Avant]

no problem Angus,

the part number is visable in the pic above and i can clearly see 054 109 145 as you said.

odd!

let me know if you do ever want a hand, always in my van flitting between centres

i am moving back to Chelmsford this weekend and ive got a bag of AAN crap somewhere, the outer covers defo there, if i can find the inner its yours and i will PM you

Sean.

[URquattroGus]

This is all sorted now, fitted a new front cover last night and used a couple of extra cable ties stratigically placed, it's going nowhere now!

Still only two fag papers worth of clearance between the cover and my PAS Pump pulley. I think this is as a result of the slightly different pulley I have to use in the quattro. Think I may have a shorter belt too.

[fasterthenrs2]

I hope you put some bolts in for inner cower, they r not there in pick, and you should defiantly find the missing ones before start the car again, they either did not get installed or r bouncing around down low between crank gear and t belt

[URquattroGus]

Yes they are all in, done up tight and with locktiite. Also put a couple of extra washers on to spread the load. None fell out, I took them out.

That picture was when I was having a look and took them out.