Cambelt Change Not Going To Plan!

[james306 0]

So started the cambelt this morning, took off the cam covers (lower ones really need replacing as they're knackered) Locked out with pins as per the haynes manual. Jammed flywheel and took the crank pulley off to find it had no woodruff key isn't there, dirt in the keyway which confirms there was nothing in there which now has me wondering if it was locked out properly in the first place or if the pulley may have spun out of line. Didn't check to see if the keyway lined up with the crank shaft as I was expecting there to be a key.

 

What also has be converned is that the cam pin just seems to sit outside the head, it doesn't lock into a timing hole within the head itself as the haynes jokebook suggests.

 

This is my first cambelt change so I'm a little cautious and any advice would be greatfully recieved. Oh, I also need to replace either the crank or cam oil seal (need to figure out which is leaking but atm it looks like both due to the oil tracking along the belts)

[james306 0]

Decided as the engine is still timed (old cambelt still on) I'm just going to get a new woodruff key and get it in as the pins still line up. Just being overly cautious.

[welshpug 1,657]

which engine is it?

[james306 0]

1.9 8v with the spring loaded tensioner

[smithy 1]

as the belt is still on why not paint mark the crank sprocket and oil seal housing and then change the belt while waiting for the woodruff key? i would assume the key for main sprocket is there just the pulley one missing?

 

as for the cam sprocket there should be a 10mm hole in head just above the headbolt with spacer on,slightly turn engine in both directions until pin drops in.

[james306 0]

It's all sorted now, found a friend with a spare 205 engine and got a new aux pulley and woodruff key. Cheers for the comments though!