Timing Belt, Water Pump, and Thermostat Change (long)

1/4 scale · 02-22-2007, 08:32 PM

Well I finally had the chance over the past couple of days to attack my overheating problem. Some of you may have been following my posts. Here are a few pics to give anyone attempting to do this job some reference. The procedure is more or less like the B5 that Andy has outlined in his excellent write-up in the Tech section. See http://www.audiworld.com/tech/eng35.shtml for this. There are some differences however that I've noted in the photos below. Nevertheless, his article on this subject is very helpful, I just wished I was more detailed taking photos to do a full write up.

Thanks to "diagnosticator1" for his help in diagnosing my problem as well as for his posts on how to adjust the pulley and tensioner. Also to Jim at Dieselgeek.com, who supplied the parts (including the OEM thermostat and some misc. helper tools) at a great price. This is a full days job so be prepared for some fun wrenching.

These are the new and old thermostat. The most recent part has the suffix "K" on the part no. I think mine was in good shape but I started here to see if it would solve my problem:

Here is the Lock Carrier peeled back away from the car. Note the ac radiator is layed down below the front of the car beneath a sheet of cardboard. This is different that the B5 which can be positioned to the right of the car. Note also the dual IC setup and JJ TIP (I love this set up!):

Here is a pic before the TB covers are removed. Note that I found it helpful to remove the single accessory belt by taking off the alternator while holding the tensioner (things are real tight without doing so). Also you need to remove this to access the electronic thermostat which is different on the B6 compared to the mechanical one of the B5. Make sure you have replacement o-rings for the t-stat as well as metal pipe that connects to it. The latter one leaked after installing the new t-stat (you can replace these parts without removing the Lock Carrier), there is a good write up on this by "Matt Devo" at http://forums.audiworld.com/a4gen2/msgs/950612.phtml:

With the TB covers removed you have this (note: the accessory belt tensioner is removed first). My red marks indicate what you have to adjust after you get the new TB and the pulley/tensioner installed. Reference "diagnosticator1" helpful instructions of this at http://forums.audiworld.com/a4gen2/msgs/1031081.phtml. Note that the cam sprocket CAN MOVE after you remove the belt and pulley, so BE CAREFUL to line up TDC on the sprocket mark well, and also mark the crank sprocket. My cam gear moved by one belt tooth due to camshaft spring pressure. It also helps to relieve internal engine cylinder pressure by removing the spark plugs:

This is what the front of the engine looks like when the water pump is removed. It takes some muscle and pulling to free this unit. Also, one will note that the timing belt is used to run this pump on the AMB engine, different than on the B5 1.8T:

And here was my problem, the dreaded plastic impeller "gone south" scenario. I had only 60,000 mi on my engine when this went bad. The TB and accessory belts looked very good, and had at least another 30,000 miles of use on them:

This is a major job but not to difficult for the technically inclined. Probably a 7 out of 10 difficulty factor. Just go slowly, and make sure you don't have any left over parts when you sew it back up!

Note: All disclaimers apply if you want to do this yourself. Wrench at your own risk, but have fun doing it! ;-)

Cheers,
1/4 scale

javanator · 02-22-2007, 09:21 PM

B5 writeup. Did you have to use any special tools that were needed to do the job, or make the job easier?

Between the Bentley manual, the B5 writeup, and your contribution here, it is looking more and more like a fairly straight forward job.

520 · 02-22-2007, 09:30 PM

MikTip · 02-23-2007, 01:19 AM

Got Bentley? ;O)

dagmz6s · 02-23-2007, 03:32 AM

1/4 scale · 02-23-2007, 04:12 AM

QuattroFan02 · 02-23-2007, 04:51 AM

initialA4 · 02-23-2007, 05:19 AM

heateris · 02-23-2007, 05:38 AM

520 · 02-23-2007, 06:17 AM

I'm sure its easy, maybe time consumng, job and you must have the right tools. You know it;-)

02-22-2007, 09:21 PM	#2
javanator Member Garage is empty, add now Join Date: Oct 2003 Posts: 1,547	bookmarks page Great writeup and pics! A lot of great additional information over the B5 writeup. Did you have to use any special tools that were needed to do the job, or make the job easier? Between the Bentley manual, the B5 writeup, and your contribution here, it is looking more and more like a fairly straight forward job.

02-22-2007, 09:30 PM	#3
520 Member Garage is empty, add now Join Date: May 2002 Posts: 21,021	That one's easy....i wonder what my 3.0 will look like....TB job-wise??...this summer probably

02-23-2007, 01:19 AM	#4
MikTip AudiWorld Expert Garage is empty, add now Join Date: Jun 2000 Posts: 29,354	Re: 3.0... Got Bentley? ;O) __________________ 2004 A4 1.8t USP Quattro 6MT K04-15/APR/TT 225 Injectors/Custom Stainless Exhaust/710N/RaceTec FMIC 034 HFC/Jet-Hot Cermi-coated & ported exhaust manifold Spec Stage 3+ with OE DMFW! Neuspeed TIP/Neuspeed Snub/Optima 75-35/AFE Pro-Dry/FSI Coils AMS Short-shift @ %40 redux(Sweet!) ST Coils/ H-Sport Anti-Sway bars/E-codes 19x8.5 OEM Audi Skinny Fives with 235-35 Bridgestone 760 Sport Skins B7 A4 brakes with StopTech Ceramic pads and Stop Tech rotors Sirius Satellite Radio Ross-Tech HEX-USB+CAN Equipped Escort 9500ix

02-23-2007, 03:32 AM	#5
dagmz6s Junior Member Garage is empty, add now Join Date: Apr 2006 Posts: 1,007	Nice work! You didnt use the tool that locks the cam sprocket in position? __________________ Current: 2006 Mini Cooper Sold: 2002 Audi A4 1.8T Quattro with K04 Valve Cover Gasket DIY

02-23-2007, 04:12 AM	#6
1/4 scale AudiWorld Senior Member Garage is empty, add now Join Date: Mar 2002 Posts: 1,353	no, but it probably would have been wiser __________________

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02-23-2007, 04:51 AM	#7
QuattroFan02 Member Garage is empty, add now Join Date: Jan 2003 Posts: 3,538	Awesome, I used your DSMIC write up before and now I can use this as well. Good job. __________________ Sprint Booster review 1 http://forums.audiworld.com/a4gen2/msgs/1014641.phtml Sprint Booster review 2 http://forums.audiworld.com/a4gen2/msgs/1015112.phtml REASON #1 NEVER TO VISIT A HOME DEPOT: THERE'S ALWAYS A LOWES NEARBY.

02-23-2007, 05:19 AM	#8
initialA4 AudiWorld Senior Member Garage is empty, add now Join Date: Jan 2003 Posts: 1,764	Uber...I guess the water pump suck! __________________ Gone but not forgotten!

02-23-2007, 05:38 AM	#9
heateris AudiWorld Super User Garage is empty, add now Join Date: May 2004 Posts: 3,645	nice work! __________________ GIAC FX ~ AWE exhaust ~ APR TIP w/ samco boost hoses ~ K&N ~ Koni/neuspeed suspension ~ 18" fliks/BF Gdrch SS A/S ~ APR snub mount ~ B&M SS ~ podi ~ RS4 pedals ~ 3.0 front brakes ~ hawk pads all around ~ european xenon headlights ~ black out grill trims ~ painted front bumper w/ zender add-ons ~ S4 door blades and rear bumper ~ ebay spoiler ~ 40% tint <a href="http://www.dvagonline.com/forums/showthread.php?t=507">the history of my car </a>

02-23-2007, 06:17 AM	#10
520 Member Garage is empty, add now Join Date: May 2002 Posts: 21,021	yeah I do. I did my 12v and CvTech's as well as my I-5 so I'm not a noob but...its a new motor. I'm sure its easy, maybe time consumng, job and you must have the right tools. You know it;-)

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