THETINTMASTER

Hello I have searched and read lots of post on this but I can't find the answer to this one. I have seen pictures that show the top balance shaft pulley alignment on the key at the 12:00 position. That leaves the notch at about 1:00. But the back cover has the reference notch at 12:00. I can't find a reference mark at 1:00. I need to know if I am to line up the notch on the pulley at 12:00 or the the key on the balance shaft. I have also read the http://www.clarks-garage.com/shop-manual/eng-08.htm on the clarks site and line 5b says "With the engine at TDC the notch on the back lip of the upper sprocket should align with the notch on the rear timing belt cover (approximately 1 o'clock position)." I am including a picture of my back cover with the reference mark at 12:00 and F'ed up key that came out of the lower pulley. I'm on hold till I can get another key on Monday.
Thank for the help. Claudio

Calmchaos

Just line up the notches.

DanR 1201

With the crank at TDC line up the rear pulley notches with the markers in the plastic cover (shown 3 teeth further on from the "O"). When the notches are correct are the "O" should be in the positions show in the diagram. The top one about 12 o'clock and the bottom one about 7 o'clock.

If not you may need to remove the pulley and re-align using the vacant other keyway instead.

What's the metal bit? Not the woodruff key I hope.

THETINTMASTER

Yes that is the "woodruff key" . Who ever had there hands in this car prior to to my purchase last month must of lost the correct key and FABED up this gem. I think I'm going to put it in a frame it and hang it in my garage as a memento. Hopefully it is the only hack job I come across. Also when they put the balance belt on they had both pulleys on 180 off and were off several teeth on the alignment of the reference marks.
Claudio

DarylJ

And the "O" showing through the window tells you that the pulley is assembled to be on the top balance shaft.

You should line up the same mark to a similar mark on the cover near the lower balance shaft with a pulley assembled to show the "U" (or possibly nothing - I've heard some pulleys have only an "O").

THETINTMASTER

Thanks for the replies. Well I could not wait till tomorrow to get a new woodruff key so I hit the local Home Depot and purchased a few 5/32"x5/8" woodruff keys. The width was good but the height and length too large, about 20-30 minutes with the trusty Dremel and the is what I came up with.


I aligned the upper and the lower balance shaft pulleys with the reference marks on the back cover (took a while to get them aligned perfect, top one was 1 tooth off), turned the tensioner clockwise (previously done wrong, shocker) put everything back together.
Fired it up and was amazed at how smooth it was. No more humming, buzzing, or sounding like it was about to disintegrate. Took the Wife and Kid out for an celebratory ice cream treat. Again, Just wanted to also say thank for the help. Now I need to tackle some those small oil leaks.
Claudio

Calmchaos

Those keys look good. Those being 100% tight isn't mission critical like the crank key.
And congrats on getting your car running smooth.

If you don't know where your oil leaks are coming from, make a new thread. I always love hearing about those! Especially if they're ones I've never heard of before.

DanR 1201

Good work, pleased for you.

alordofchaos

Nicely done, and welcome to RL!