Timing belt fitting and clutch slave cylinder removal...

[gerard]

Okay, first the succesful bit. The clutch slave cylinder is out of the
gearbox. I stood the box on its end and used some pipe type spark plug
socket (OEM thing) as a punch and hammered the thing out. Those things
are in there quite solid, aren't they? :) I can now see if I can get a
new one from somewhere.

I went to the VW/Audi agents this afternoon with the timing belt. They
pulled out another belt for the MC engine and it was definitely longer
than this belt I have. The belt I have is marked as 22S 109 119 and is
apparently also indicated for the Eurovan/Vanagon/Microbus engines. It
is the 19mm wide belt. The belt they showed me was clearly the older
belt with the wide square teeth and also 18mm wide. The older belt is
034 109 119. ETKA indicates 074 109 119 for the super-torque thing, but
no-one picked this up at the dealership.

I've fitted all super-torque items to my engine. The damn mechanic who
stripped my car also made off with my cam and crank pulleys and relay
roller so I had to get a new cam pulley and the engineer who built the
engine supplied me with a non-supertorque crank pulley. I replaced the
crank pulley with one of the supertorque items. Basically, I matched it
all up to the waterpump pulley on my old water pump. I replaced the oil
and water pumps. The water pump is a VW/Audi OE item and it came with
the supertorque pulley just like the old water pump I had.

The water pump slides perfectly, and it stops at the bolts. When it
stops against the bolts, the water pump is touching a point on the oil
pump. The oil pump isn't blocking any travel as at this point the bolts
are right against the edge of the groove in the water pump.

I took this picture (sorry, it came out a bit dark):

 http://www.2226.co.za/images/timing-belt-fit-001.jpg

What can be wrong in this setup?

I'm messing around in ETKA right now and I've just noticed that they
indicate a 74mm relay roller (069 109 243B) for the older belt and a
68,7mm relay roller (074 109 243) for the supertorque units. I can't
measure it right now, but I think this is the cause of my troubles. I
either ordered the wrong thing way back when, or I was supplied the
incorrect thing.

I have also noticed a small plastic zip-lock bag in amongst my parts
today. I opened it and found some sort of temperature sender. A quick
look at the engine and I can tell this is the oil temp sender as the
damn engineer also kind of seemed to have "overlooked" the fitment of
that. What did I pay people for? :P

G.