Rebuild: Turbo Minivan, Part 1

[Dave]

FYI, next engine job, just unbolt the bracket from the side and rear and let it hang on the K-member.

Ya certainly would have been easier....kind of sad that I can rebuild an entire engine but can't figure out a power steering bracket. It won't damage any seals or the rack if I drive it with the pump not hooked up will it?

[Vigo]

Not hooked up to the engine by the belt, or not hooked up to the rack by the lines?

If you want to drive without the pump hooked up to the rack you need to at least loop the lines so that it doesnt push all the fluid out and run the rack seals dry.

[turbovanman²]

Ya certainly would have been easier....kind of sad that I can rebuild an entire engine but can't figure out a power steering bracket. It won't damage any seals or the rack if I drive it with the pump not hooked up will it?

You can but it will blow all the fluid out, so you need to hook it up or do as Vigo said, loop the lines.

[RoadWarrior222]

Dunno if you're messing around with it from on top, but I remember messing with it on a 2.5 TBI van from underneath, reaching over the K-frame.... don't recall it giving me any unusual hassle.

[Dave]

Sorry it's been a while since I've updated. Got it running last week and took it for a drive around the block. It's a tad noisy at cold idle but once completely warmed it quiets down a bit.

Everything seems normal. I'll start putting some miles on it next week. I'll try and post pics and video tomorrow.

-Bryan

[RoadWarrior222]

It's a tad noisy at cold idle but once completely warmed it quiets down a bit.

You're aware that's it's a T-M right? ... oh NM, you've been driving that Audi too long

[Dave]

I can't seem to properly tension my timing belt after installing the Fidanza cam gear. I just ate a new belt within a few seconds as you can see in the picture it touches the snow guard. I tried rotating it every way and it appears to hit no matter what. Any help?

[turbovanman²]

Compare the Fidanza diameter to a stocker.

Try turning the tensioner the other way?

[Dave]

Simon, I tried reversing the tensioner with no luck. Looked at dad's van last night and there clearly is a large tolerance between the belt and guard. Now that I'm thinking of it I may need to retard the cam a tad, I didn't bother even setting everything TDC as it was just a simple belt change. This all may not even be an issue. I'm surely overlooking something.

[Aries_Turbo]

are you using the smaller plastic tall deck tensioner pulley?

Brian

[turbovanman²]

Simon, I tried reversing the tensioner with no luck. Looked at dad's van last night and there clearly is a large tolerance between the belt and guard. Now that I'm thinking of it I may need to retard the cam a tad, I didn't bother even setting everything TDC as it was just a simple belt change. This all may not even be an issue. I'm surely overlooking something.

Cam timing doesn't affect how the belt rides.

You still need to match up the pulley's, something stupid is off, lol.

are you using the smaller plastic tall deck tensioner pulley?

Brian

Good idea, but that should give him more room, not less.

[Dave]

are you using the smaller plastic tall deck tensioner pulley?

Brian

I've had no problems with the setup before the Fidanza cam gear. Timing went bang on first time with all stock pullies. I'll have time to check it out Friday.

[Aries_Turbo]

that doesnt make any sense. the cam gear should be exactly the same diameter as the stocker.

Brian

[Dave]

that doesnt make any sense. the cam gear should be exactly the same diameter as the stocker.

Brian

I put the stock gear next to the Fidanza a few days ago and they are the same.

I measured the pulley and came up with 3.165" on the OD of the outter-most lip.

I may be able to look at it some more Saturday if I'm not working in the morning.

[Reaper1]

Maybe you have a longer than stock belt?

[Dave]

Maybe you have a longer than stock belt?

Possbile, I verified the part number is correct, that still doesnt rule that theory out though.

It does run now, however, still not correct. I basically said f*ck it and threw it together as best as I could with what I had. Measured the clearance with my feeler gauge... .015" Scary but it works. Drove it around the block no problems other than my smokey-desktop turbo.

Onwards!

[Shadow]

Stupid sounding Q, but you did spin the tensioner clockwise to the belt, and Not the reverse, correct?

[GLHNSLHT2]

looks like it's touching the snow quard on both sides of the crank pulley?

[Shadow]

I'm guessing that's just the angle of the pic? I seem to remember someone having this problem some years ago and it turned out to be the wrong belt in the box. I believe the part # was right, but it was a tall block belt?

Did you dble check the belt length?

[Dave]

Stupid sounding Q, but you did spin the tensioner clockwise to the belt, and Not the reverse, correct?

Fair question, but correct I did spin it clockwise so it's pointing to about 1 or 2 o'clock.

looks like it's touching the snow quard on both sides of the crank pulley?

Right, it's very close on the entry side of the snow guard as well. I had a bit more than .015" on that side. Something is still not right, but I've checked every which way and cannot come up with a different alternative. Perhaps I'll make a few measurements on my dad's van and compare it to mine and see if something, somewhere became mismatched while assembling the engine...