Spot what's missing!

[Tanz]

Changed the cambelt today and was just admiring my handy work when I noticed something was missing.



Correct me if I'm wrong but shouldn't there be a bolt and washer holding the auxiliary pully on?
The last time I removed that pully was 2013 - see below


It looks like it has sheared off. That bolt isn't really under any strain so maybe I over tightened it and cracked it but didn't realise and in time it has fallen off.
I always tighten bolts to the torque specified in the service notes so can't really understand it. I think I have been driving with it like that for a while. Doesn't look like a new break

Question now is what do I do about it

[Lotus-e-Clan]

For now, I'd think about asking Lotsa bits if they have a spare oil pump/dizzy assembly, then address the broken bolt off the car.

Or as a stop gap (assuming you need the car whilst waiting for the part), I'd drill and tap for a slightly smaller diameter (hi-ten) threaded bolt and snug it up with some thread lock. Then address the issue after you source a spare assembly? Looks like it hasn't moved for a while since the bolt broke, so it's 'well-on' and therefore a small bolt rescue wouldn't be too scary a prospect.

[Pete Boole]

That looks like the original washer that is supposed to have a countersunk screw in it, but the other picture shows a hex-headed bolt and standard washer??

Pete

[Marten]

It looks like it has sheared off. That bolt isn't really under any strain so maybe I over tightened it and cracked it but didn't realise and in time it has fallen off.

or maybe some corrosion under the washer added extra oomph

I always tighten bolts to the torque specified in the service notes so can't really understand it. I think I have been driving with it like that for a while. Doesn't look like a new break

Question now is what do I do about it

Try the easy things first: give it a couple of taps with a punch to see if it willl move and if it does walk it out with a centerpunch tapping around the circumference

[Tanz]

I have removed the auxiliary housing and the shaft. Talking to Mike at Lotusbits, he can supply a replacement shaft and pulley. I will have a go at getting the bolt out, but I will still need a pulley. Ive got 2 old cam pulleys. Are they the same as the Auxiliary pulley?

Housing with shaft and oil pump.


Shaft Removed


End of shaft with broken bolt


Damage to pulley key way

[AndyC]

Yes, pulley is the same, doesn't matter what angle one it is (104, 107 etc).

[Lotus-e-Clan]

Wow. Didn't realise the pulley was that loose!

You were lucky the belt stayed on.

[DavidOliver]

With that damage to the pulley I suggest you inspect the Woodruff key and it´s seating in the shaft. Any slight damage and you need a new shaft, no point removing the sheared bolt.

Dave the cog.

[Pete Boole]

Could this be at the bottom of your ignition timing issues, or have you already sorted that?

Pete

[bash]

Loose nuts only belong on the steering wheel.

Bash

[Tanz]

Wow. Didn't realise the pulley was that loose!

You were lucky the belt stayed on.

The pulley and the key were jammed on and I needed a puller to get the pulley off.

[Tanz]

With that damage to the pulley I suggest you inspect the Woodruff key and it´s seating in the shaft. Any slight damage and you need a new shaft, no point removing the sheared bolt.

Dave the cog.

Thats what I have been thinking. The key is damaged and the slot it fits in distorted.

[Tanz]

Could this be at the bottom of your ignition timing issues, or have you already sorted that?

Pete

I was thinking the same Pete. I found the cam belt was a bit loose and tightened it back up using a Krikit and that seemed to improve the problem a bit but it didn't fix it completely. Will be interesting to see how it goes after I have replaced the shaft and pulley. I have to say I have been very fortunate not to completely wreck the engine.

[Tanz]

Loose nuts only belong on the steering wheel.

Bash

[Tanz]

Could this be at the bottom of your ignition timing issues, or have you already sorted that?

Pete

I was thinking the same Pete. I found the cam belt was a bit loose and tightened it back up using a Krikit and that seemed to improve the problem a bit but it didn't fix it completely. The cam belt was probably loose because the pulley had slipped on the shaft. Will be interesting to see how it goes after I have replaced the shaft and pulley. I have to say I have been very fortunate not to completely wreck the engine.