Major facepalm moment - HALP PLEEZE!

**Jace** · 29-04-2011, 05:37 PM

After getting the car running again (dodgy #9 fuse meant the idle fuel valve was stuck shut), then relaying my headlights, I finally got around to painting the cars upper timing belt cover.

When I was putting it back on the engine, I dropped a washer from the front lower bolt (the waterpump one) and it bounced off the water pump, onto whatever bit of the block between it and the intermediate shaft pulley.

I was trying to fish it out from there, but it fell further down and is now (presumably vertical) stuck between the crankshaft timing pulley and the block, resting on the lower timing cover.

I tried for a good hour and a half to fish it out. Magnetic pick up tool is a little bit useless because everything there is metal... It's too big to fit in anyway.

Only way I can see me getting this ****ing washer out is to take off the crankshaft pulleys. I don't see driving around with a loose washer in there as such a great idea. Said washer is the size of a 10¢ piece.

The gap between the bottom belt cover and the side one (that goes up the back of the block) is a bit too small to simply roll the washer out the back.

Are those lower belt covers a part of the block? It almost looks like they're bolted on (hard to see because of the grease and road-****). I think to take those off, if they're removable, I'd have to take off the crankshaft pulleys anyway.

SO, how should I lock the engine to undo the 19mm crankshaft pulley bolt, so I can remove the crankshaft pulleys so I can get this POS washer out?

I'd appreciate the help. Thanks in advance!!!!!!!!!

**Preen59** · 29-04-2011, 07:13 PM

Wind the engine over with a spanner and see if it drops the washer out first.

You'll need a rattlegun to undo the bolt..

Or you can make a spanner with 2 holes in it out of some flat bar that you can screw to the pulley with the bolts that attach the water pump/alternator pulley.. If that makes sense?

Pete Jones has a thread on it I think, with pictures..

**Jace** · 29-04-2011, 07:22 PM

I get it! Suppose I'll make one of those tomorrow.

I looked it up, the way of doing it with a jammed breaker bar and using the force of the starter to loosen the bolt seems a bit dodgy to me!

**Peter Jones** · 29-04-2011, 08:16 PM

Compressed air might be another option.

Here's the tool I made. You're welcome to borrow it.

**Jace** · 29-04-2011, 08:25 PM

Thanks for the offer Pete.

I might chance a drive to a mates workshop tomorrow morning. I'm sure the washer is vertical, and because I can't get it out I don't think it'll move around too much.

****, still kicking myself for this. Lucky I noticed though I suppose.

**h100vw** · 29-04-2011, 08:32 PM

I don't think the 19mm bolt has to come out, undo the 4 6mm allen bolts and the belt pulley will come off. Might need some persuasion.
Might need to take the water pump pulley off too.

Then the lower cover should come off easily. In my experience, it's good not to undo the 19mm crank pulley bolt. That's a G60/16v/digifant experience though.

Gavin

**Jace** · 29-04-2011, 08:35 PM

On that note, I found that one of those allen head bolts was stripped out, just to make matters a little bit worse.

Thanks though!

**GRN_VAGN** · 29-04-2011, 09:59 PM

timing cover will come off just by taking the pulleys and belt off.
You dont need to touch that crank bolt FWIW

**h100vw** · 30-04-2011, 09:46 AM

Originally Posted by Jace

On that note, I found that one of those allen head bolts was stripped out, just to make matters a little bit worse.

Thanks though!

That's easy, M8 spline drive hammered into the cap head will work. Done it to lots and it never fails. M8 is the same as the one for undoing the CV joints on all but the earliest mk1s I have seen.

Gavin