More timing belt how-to instructions, as if you needed more.

[john s]

Did the timing belt replacement, have a few suggestions (figure all day job).

1) Go here, great instructions on removal:
belt removal instructions link
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2) To easily find TDC, remove #1 sparkplug and put something that will stick out so you can see it while you rotate the crankshaft. I found sparkplug and piston top soaking wet! Camshaft mark small and you can't see it while rotating crank. Verify mark on camshaft pulley, if not there, rotate crank 1 more revolution (4-cycle engine). This is done for insurance purposes if you lose chalk marks.


3) Don't tie back coolant reservoir. Lower hose clamp scratched my aluminum charge pipe and hot decal. After draining system I found crud in reservoir, so remove and clean out.

4) Drain coolant from lower radiator hose spout and oil cooler line. Found this loose connector shell hanging on coolant line. Audi tech gift?
5) Mark old timing belt next to camshaft mark and tooth closest to raised teat on crankshaft pulley (in case mark gets washed off, it will when pump comes out).
6) After you get water pump out, motor mount that has been a real PITA will fall out. For now leave it be.
7) Transfer belt marks to new belt.
8) Install new tensioner, use locktight.
9) Install new tensioner pulley, use locktight.
10) Put PITA motor mount back near engine.
11) Put new belt near final position, looped inside mount. Pay attention to mark locations, if not there's a 50:50 chance you'll need to flip belt (marks are not 180° apart).
12) Finger tighten long motor mount bolt to hold in position while you position belt.

13) Put belt over camshaft pulley mark, clamp in position with welder's clamp or vise grip.
14) Thread belt over tensioner pulley, loop over crankshaft pulley.
15) Pull belt down and slip over crankshaft mark.

16) Wedge sponge or rag between belt shroud and crankshaft pulley to hold belt into position.
17) Take motor mount bolt back out, let mount go to the left side, up and out of way.
18) Wipe coolant on pump o-ring.
19) Put belt over pump pulley, place pump impeller flat against machined side of block, slide pump up and over into position.
20) Thread top screw into pump, leave loose, then thread lower right screw as you push pump forward. Remain screw goes right into position, Tighten all screws. Make sure to use locktight.
21) Belt is in position, without forcing over camshaft pulley or worrying if installed off mark. You can now pull tensioner pin.
22) Continue putting parts back, make sure you have none left over!

I also changed the thermostat, got ECS deluxe kit with motor mount bolts.

ECS thermostat appears to be a piece of junk, bulb is crooked and spring much weaker than stock. Part box has same number, but not same part. Kit has 8 motor mount bolts, 4 we use and 4 we don't, missing 3 we do need. Belt part was "B", original "A", dealer has "E", don't know what difference it makes. My plastic water pump impeller was fine, looked like new, others have reported cracked units.

[TTinCT]

[ncttrnl]