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Thanks to John for the photo! The teeth that are shown on the pulley should run the complete width. What has happened is a perfect machining of the pulley by a bolt from somewhere else. Read on to find out where and why.
For those of you in the know, the Mark 1 MR2 has a non interference engine design meaning, that if the cam belt snaps or just stops turning no damage will occur to the valves or pistons because there is a big enough gap even at full valve opening. Oh really?? Anybody care to try that theory out on their own car? Didn't think so.
I did............. This is my story.
I was at the rolling road getting my car tuned, see separate story, when I first thought I heard something amiss. Being the careful owner I am I just ignored it and carried on. Sounded like a ticking noise, I thought it was just a stone or something caught in the treads.
Some time later I was driving along the road when I heard a distinct squealing noise coming from the engine. I pulled over and no pedestrians or cats were to be found under or in the car. Strange thought I. I just keep on driving.... The noise steadily got worse to the point where I actually had to go to the garage.
The garage were keen enough for the work but very dubious about the amount of work they would have to do to get into the timing belt area. We had established that the noise was coming from the timing cover and there is not a lot of space in there to play with.
A day later still they had not looked at it so I just asked "Do you want to or not" to which they replied "Actually no, it sounds a right pig to work on so no ta" Brilliant!
I finish my day at work and then after dinner I go down to the car with me torch. Take off the timing cover and what do I see glinting back at me?? A bolt of unknown origin stuck behind the timing gears for the cams! I pulled it out and then started the engine and guess what? No noise. Great thought I, it fixed. Spoke to me mate John and we both had a look at it and decided that the bolt was from the engine mount but hey, there were 2 more holding it together so why worry. What a daft decision as it turned out. I should have spend the money and got it checked but I didn't and hence the picture at the top of the page. The timing belt had a nick in the middle of the teeth but nothing serious and so I left it in.
Barely two weeks later I come out of work last thing on a Friday and turn the key for the engine. Nothing but a faint but distinct clicking noise. Oh drat. Now at this point I thought the starter motor had gone but after work John, again, and me had a look and with the car in gear the starter motor would push the car forward. Oh dear, bottom end turning top end not. Off comes the timing belt and we get greeted by a shredded timing belt and loads of belt shavings. The belt was completely slack and the bottom end had been turned over.
After much discussion we decided to take the car to back to the rolling road people and get them to assess the damage and repair if poss. Quick phone call on Saturday morning and the car was towed along the M8 to the garage. And then the waiting began.
The first news was not good.
After waiting nearly 6 weeks, including christmas, I finally got the car back rebuild and running good. YIPPEE. It runs like a good 'un still but that repair did cost a fortune. Not to mention the hire car in the meantime. Could of put me deposit down on a turbo.......... Stay tuned as they say.