With everything working as it should, last Saturday saw the cars first test drive. All went well till I returned home after a high speed blast over the motorway. During the last few miles there was a rather clear knocking sound coming from the engine. So after putting her back in the shed it was time for a quick check under the bonnet. I was met by a rather disheartening sight, a big oil spill around the oil cooler thermostat . And the knocking came from the front of the engine, clearly not good. Luckily a quick check of the oil level and the oil cooler hoses showed nothing wrong there. Inspecting the oil spill in more detail showed that the oil was coming from the front pulley’s oil seal. But as it was getting late and all my tools were at home I locked up the shed and went home with mixed feelings. But not before I had found out that the front pulley was wobbling about a bit and had some play.
This bolt, which was sold to me as a normal European engine front pulley bolt almost 20 years ago, clearly is too long. Checking it against one from an AC equipped US spec engine I have lying around in the shed, proved this. Luckily I had the old bolt still lying around in a box so that problem was solved pretty easily.
As you can see the pulley is very badly damaged. But luckily the crank shaft and woodruff key showed no visible signs of damage. And the aforementioned US spec engine provided me with a new front pulley. Together with a new oil seal all should be OK now up front.