Audi R4R

So here it is,..

<img src="http://pictureposter.audiworld.com/32851/pulley1.jpg">

<img src="http://pictureposter.audiworld.com/32851/pulley2.jpg">

Sucks to be me,...

Steve

RussB

Is the one with two keys aftermarket?

A (very good) motorcycle mechanic friend tells me that keeping keyed timing belt pulleys on race modified Ducati 915/996's can be tricky -- especially aftermarket pulleys, which are often lighter in weight than the steel OEM ones. He says that his technique is to use a good solvent to carefully clean the tapered surfaces where the pulley and shaft meet, apply maybe 10 percent more torque than specified to the fastening nut, and to use red Locktite on that nut's threads -- even though there's a stock tab washer that's supposed to keep the nut from turning. He says that the nut absolutely must not loosen even a bit and doesn't trust the tab washer to do this.

Lucas_Gchips

I spoke a lengthe with Mechanic Shop.
They say the Key is only used for locating whilst tightening Bolt, Thats all.
He has never seen a key Fail like yours unless the Bolt on pully was loose or not fully tightened.
He went into lengths about this issue, as he has seen similar damage before, but in ever case he stated the Bolt was not Fully torqued.
Then he also explained, Porsche have done away with those locating keys, The spot is still there for them, but no key present.
Its too late now for you to check, but would have been interesting to use a torque wrench in reverse
to see what tension was on your bolt.
So would you say who ever assembled your engine
would put their life on the line and say they did torque it correctly??
I am not being a smart **** by above comment, but had a in depth talk about it with a very qualified and experienced Mechanic tonight about it, as i was prepared to get mine looked at.

P.S.
Had my car on Hoist to look at possible engine mount probs, turned out Trans Mount is broken.

Thats why i tore turbo hose at drags, as engine is moving heaps.

Audiboy

requires a lot of torque to spin. If so, the few teeth of the timing belt engaged with the bottom crank gear will be the first to go. It probably does have something to do with a bolt out of torque or something causing it to go out of torque (vibration perhaps - harmonics)

squidix9

<center><img src="http://members.verizon.net/~vze4phja/images/timegsm.jpg"></center><p>and take out a valve stem lock at the same time.

How do I know this you ask?

BTDT

My cam gear was torqued on pretty tight. It was locked with a white style Loctite on the threads.

I had to use my impact gun set at 240 ft/lbs to get it off.

And whoever said it, correct, even with a super high lft cam, and solid lifters, it does turn over pretty easily(with the plugs out).

nscirocco

when you get the new bolt, check it's length, there's different ones .. and some dealers sell crappy jobber bolts, don't trust the parts guys

some vw guys drill through the pulley and the crank then install dowels

-nigel.

Audi R4R

There's a few other local VW people in my area that have confessed to having my same problem. There have been at least three very well respected mechanics working on thse monster 1.8T engines, and I do not believe it is possible for each of them to incorrectly torqued.

I spoke to my mechanic about this and he's a good friend as well. If I were you, I'd figure out some solution.

Even if you're totally right,... I wouldn't want to take that risk if I were you. It's just an unnecessary waste of money.

Sorry to hear about your engine mount issues,... how do you plan to solve this?

Lucas_Gchips

Many laps of race tracks, a few drag runs, many street runs plus daily driver, no issues yet.
I will stick to advice from my Mechanic, he is porsche trained and worked for Weltmeister for quite some time and worked on many race porsche engines. He is insistant that Key is not meant for any load bearing what so ever other than to locate pullies whilst you tighten them up.
He also said that if you are carefull in location of pully, you should be able to tighten it up with out the use of location key at all.

Tell me, how many miles did you do on your rebuilt engine when your "key stripped"?
Did any machine work get carried out on your crank around that area?