Balance Belts and Headlights

[Porschamaniac]

OK, firstly, let me say that these two are not connected (I hope).

After many weeks (working only at weekends) replacing both belts, all oil seals, the water pump and tensioners, I finally got it all back together last weekend. Turned the key and........hey presto.........started first time - deep joy. However, my joy was, somewhat short lived, when I realised that I'd refitted the lower balance pulley 180 degrees out of synch (apparently, the 'O' no longer means Oben - or up - after about 1985 - and I have an '86 engine in my car).

Still, no problem - only meant a couple of hours dismantling the front covers and balance belts to turn the pulley around. Job done - only took a bit over an hour. However, on putting it all back together, I just cant get clearance between the balance idler and the belt. Before the second stripdown, all was good - managed to set the required 0.5mm gap (with 1mm preload applied to the top belt).

It's as if something has changed when it all came part to swap the pully around! With the idler at it's slackest setting, I can get it just kissing the belt (creates the smallest perceptible amount of deflection in the belt). It's got me foxed - even went out and bought another new idler pulley (in case something had changed). But, nope! I'd really appreciate any thoughts on this - the only thing I can think is that perhaps the idler stud has deformed slightly - or maybe something changed with the tensioner?

Anyway, having got it all back together, I took it out for it's first proper drive in many weeks. It started to overheat, so I made for home. It was getting dark by the tie I got home, so I switched the lights on - they popped up as they always do - however - when I switched them off, the lights went out, but won't retract. When I try to wind them down by hand, I can feel resistance on the manual winder - it's as if the motor is contnually trying to push them up. I also noticed that the motor seems to be getting hot - not sure if that's because it's in the hot enging bay, or because it's got a continual load applied.

If I disconnect the battery, the lights can be easily wound down by hand and stay down, again, when switched on, they pop up as normal - but refuse to retract until the power is disconnected, when they can be wound down. I'm guessing that this could be down to failure in the position sensor swithces in the motor unit, but, again, it's left me scratching my head!

As always, any thoughts on this will be really appreciated.

Wishing all happy new year and all the very best for 2009.

[many944s]

On the balance belt- did you be sure to turn the tensioner the proper direction? The balance belt and cam belt tensioners are to be turned different directions (clock-wise and counter clockwise) to apply tension. The balance tensioner should be turned clockwise to apply tension. If it is rotated the other direction the belt is "lifted" away from the idle roller.

On the headlight issue, I have had a devil of a time adjusting the knob to get the headlights to function properly. It's been a long time since I adjusted a set, but it was a LOT of trial and error to get it just right.

-Nick

[Porschamaniac]

Hi Nick,

Thanks very much for the reply. I think that the bel problem probably is something to do with the location of the tensioner - I had a real job getting the tensioner pulley on, so I guess the position may not be perfect. Time to get the covers off again, I guess!!

Also, looks like a have a few hours fiddling with the manual light raiser to get the lights working again.

Thanks again,

Ian.