So, a few goodies arrived today, one being the belt, I went and tried it and it's on! But, it isn't as tight as I would like, there are a few options I have thought of. Get another belt orrrrr, space the alternator bracket out to get the tension.

Discuss

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get a shorter belt, dont forget when they come off or snap they can get pulled into the timing belt and kill the engine, just not worth the risk!

 

If it was me, id just go down to euro car parts and get 5 different belts all 10mm apart, fit the best one and return the others, simples!

So after a bit brain storming I came up with the the solution to make the belt fit, all it too was 12 1mm washers, 2 behind all of the bolts on the bracket to shift it out enough to take up he slack. Easy solution!

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Had a few hours on it this morning, managed to get some more wiring tidied up, and the vacuum control box relocated and all of he tubes ran to it aswell.

All fastened in place.

Just need to protect the main harness with some tape, a bit more tidying up then it will nearly be there!

Also I don't need the coolant sensor anymore as I have got rid of the header tank, will it be okay to just lop it off and tape the ends??

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This car is a beast.. Im jealous..

Ackadappa - haha thanks man!

Continued to take things off the fabia, I removed the fuel line housing which was unnecessarily difficult and large. It has made a good difference though!

Also relocating things out of sight, luckily the wires are long enough!

slightly unsure about the fuel filter, I need to mock up the fuel lines to see where the final placement will be!

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Coolant sensor will need the ends joining together so the alarm doesn't go off constantly. Also, where the wires are running through the holes in the leg and scuttle you really need some open grommets or grommet strip so you don't have issues down the line with shorting out cables to the bodywork. Wouldn't want all your hard work to go up in flames. Its looking amazing though, can't wait to see more progress

The coolant sensor has been joined together at the ends all of the wires going through the legs, are wrapped in cloth tape then encased in armour core, so they don't rub through and like you say short on the inside of the leg, your right man, I'm buying a fire extinguisher soon aswell haha thanks for the decent write up man!

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Got rid of the washer bottle filler neck, a simple section of pipe and a plug. Easy.

Also I finished plumbing in the expansion tank delete, shortened a few lines and routed the nice and neat. The blue cable ties are just to hold it until I get some thicker/stronger ones

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I wasn't happy with how close the fuel lines sat to the alternator, so I made a bracket to just lift them clear.

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That looks wrong mate, the back of the belt should run on the middle pully not the teeth part

Edited 29 October, 201510 yr by 12345Jay

That looks wrong mate, the back of the belt should run on the middle pully not the teeth part

 

We have a winner!

 

The tensioner pulley presses against the 'flat' side of the belt, hence why the tensioner pushes backwards towards the cam belt and to slacken it off you put the spanner on top and push it back, bringing the pulley forward. Tension should be proved by the spring action of the tensioner not by spacing it out with washers.

 

And any dealer should be able to supply a non-AC belt. I got one from Seat for my 1.8T and AFAIK there isn't a 1.8T Ibiza without AC but they had no issues supplying the belt

Your right! I think from staring at it for too long I. Convinced myself it was correct haha I will source a new belt this week.

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If anyone could shed some light on this I would be forever in your debt (terms & conditions apply)

This is the fog light plug with 5 wires coming from it, 2 of the wires are not connected and I have no idea where they goto??

The only possibility that I came up with was this, the radiator sensor has 3 wires from it, 2 of which match the wires from the fog plug, and the last wire form the radiator plug I presume is an earth?

As I am still working on the engine bay, I have taken the engine mounts off to be painted, in the process the gearbox mount is getting smoothed (holes welded up and joints welded up)

I have sanded the part number and a few casting marks off the left hand engine mount aswell.

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More parts for powder coating!

Does anyone have any ideas of how to get this out??

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So that the new aux belt fitted, fuel filter and brackets in their new location, and cardboard templates mocked up for the new covers that will be welded in, the side where the junction box is will be hinged in case I need to access it

Loved how my car used to look!

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That is some serious dedication

Looking forward to see it done. What did you do for the aux belt in the end? Did you change a pulley/ tensioner as well?

Its getting to the point now where I am uncomfortable and well out of my depth, but I will battle through! ahah you and me both buddy!

 

I found a belt that fit (965) is the belt length you need, the tensioner setup on a non AC car is different hence why I coulden't find one and get one to fit. 

I'm looking forward to this to see how it comes out.

Cheers ant! The scary thing is not many people have a smoothed pd130 bay so there is no reference or rough ideas to go off!

This is the turbo setup (if i go for it) is the one i would be getting! Awesome!

 

 

 

 

Gtb set up?

Yeh a gtb setup but mounted on top

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Edited 24 November, 201510 yr by skodalad

What was supposed to be a night of tidying things up ended up in me ripping things off it again. I'm going to reprint the engine as I wasn't happy with the finish.

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