Decided to replace the Timing belt on Sue's B5 Passat today. 74,000 miles, and no issues. I called the dealer early last week, ordered the timing belt, belt tensioner, and pulley, and she picked them up at lunch on Tuesday, since she works close by.
I started at 'bout 9:30, and after fightin' 4 soft Allen head bolts for 2 hours 'cause they stripped, I get down to the Belt and find out that the tensioner they gave us was WAAAAAY wrong. I call the dealer to inquire, only to find that what 'cuz gave Sue was the INTAKE CAM DRIVE CHAIN TENSIONER
. Well, it being Saturday, and 12:00 noon, I had an hour to drive an hour and 15 minute trip to get the right part, and my means of driving was not quite in operational order at the time, so I decided to re-use the old tensioner, as I have done on HUNDREDS of other cars before.
That was a big mistake. What's worse, I couldn't avoid it.
I finished the job, cleaned up my dirty paw prints, and my dirty paws, then proceded on my way home from the shop (where I work). After traveling 250 yards, with a total run time of 20 minutes, the gimpy, Mickey-Mouse, spring-clip ball joint havin' tensioner failed. Engine was turning 3200 revolutions, and yes, I heard the "Death Rattle".
I haven't got the head off yet. All I have left to do is get the right tool for the head bolts, then unbolt the head. Kinda cool, it comes out with the cams still inside, and you can take the exhaust manifold off after you get the head off the block. Just 3 bolts hold the turbine housing onto the manifold, and the turbo can stay in the car.
In lieu of recent events, my 2270 will be staying as a mocked-up short block, and my 1303 will live in the woods, amongst the tall Pines, and Wintergreen for an undetermined period of time, and Hummbug just got promoted to FULL daily driver status once again.