Important Timing Belt Replacement Information
#1
10-01-2012, 05:37 PM
Important Timing Belt Replacement Information
I've done 100's of TB changes in Audi's & VW's. This weekend I did one on a 2002 2.7T. The owner had previously done it himself, it wasn't throwing codes or misfiring, but it was running like pure ****. Here is how to not be in that position.....
-There are many shortcuts that lead to bad places, not using the cam lock bar & crank locking pin is one of them. Placing the crank pin is a PITA in the 2.7 but more than achievable. Other engines are far easier lol.
*!*Set the engine to Intake TDC (larger holes on the "wings" should be inside facing each other) by turning the crank CLOCKWISE ONLY!!! No need to pull spark plugs, just man up & turn. Once it's on intake TDC, get under there and put the pin in place. It usually takes an extra hand to rock the crank slightly back & fourth to get the pin all the way in place. Make sure it's all the way in, you don't want to strip the hole in the crank shaft.*!*
-To reduce risk of catastrophic engine failure, Change your water pump, thermostat, tension roller, idle roller, timing belt & second only to your water pump A NEW DAMPENER! Not changing a 10 year old dampener will lead to insufficient tension on the belt & opens the door to a plethora of possible problems.
- In order to achieve perfect timing you MUST pop the cam gears from the keyed ends. Its really not that serious & the "wings" are keyed onto the ends of the cams so they only go on one way. Buy a set of Cam Seals from a retail store. When you pop the Cam Gears, you'll have easy access to the seals. If you detect ANY oil at all around the seals, replace them. If not, just leave the current ones in place & return them when your done. Better safe than sorry.
THEN FOLLOW THESE STEPS
1. Replace water pump, thermostat, idle roller, tension roller (Cam seals if applicable) Dampener (leave pin in) & clean up the area in the rear timing cover.
2. Place the cam gears on the Cam Shaft Ends (loosely so they spin, but snug enough that they cannot move side to side), put the "wings" back onto their keyed location then hand tighten the Cam End Bolts, making sure the gears can spin freely.
3. Put Cam Lock Bar into position
4. Replace belt. Start belt around crank gear, over the idle roller, over the drivers side cam gear, under water pump, around passenger side cam gear then finally use some mechanic finger strength to push that bitch over the tension roller. When the gears can spin freely, there is no need to "stretch to the right tooth" tension gets distributed evenly across the entire belt (ding ding ding!)
5. Compress the dampener enough to pull the pin, once pin is pulled and dampener is exerting force on the belt, set your Torque Wrench to 15NM/11ft lbs/132 inch lbs, place an 8mm Allen on the wrench & torque the belt. It's hard to get it there & in some cases will not get there, but try as hard as you can without breaking your new belt.
6. Now Cam Gear Position is perfect, tension on the belt is even between all linkage! Now time to wrap it up! Pull out your Torque Wrench and a 16mm bit (*!*Must only be a 6 point*!*). Set wrench to 55NM/40.5ft-lbs/486 & a 1/4 turn inch lbs. Torque the Cam Shaft Bolts to spec & guess what... Your done & you did it right!
TIMING COVER REPLACEMENT
Save yourself the PITA and read this...
1. Thread Accessory Idle Pulley Bolts on LOOSELY
2. Place Lower cover (behind harmonic balance pulley) and loosely thread the two bolts.
3. Put drivers side cover on. Make sure the part that goes over the water pump is over the metal piece of the idle pulley, but the rest of the cover is under the pulley. Thread the bolts in hand tight.
4. Place center cover in its place, make sure at this point the "puzzle pieces" are fitting together how the Audi Gods intended, and snap the metal clamp fasteners in place. If the bottom fastener doesn't easily snap into place you need to reconfigure everything to fit properly.
5. Place passenger cover in it's rightful place and thread the long bolt in hand tight.
6. Check to make sure the "puzzle" lines up then tighten the accessory idle puller bolts (while making sure everything aligns). The design for these bolts baffles me. Pure stupidity Audi.... Then tighten the lower covers two 10mm bolts, and finish off with the rest of the T30's in a counter clockwise order.
7. Figure the rest out yourself! If you can't I don't know how you got this far!!!
-There are many shortcuts that lead to bad places, not using the cam lock bar & crank locking pin is one of them. Placing the crank pin is a PITA in the 2.7 but more than achievable. Other engines are far easier lol.
*!*Set the engine to Intake TDC (larger holes on the "wings" should be inside facing each other) by turning the crank CLOCKWISE ONLY!!! No need to pull spark plugs, just man up & turn. Once it's on intake TDC, get under there and put the pin in place. It usually takes an extra hand to rock the crank slightly back & fourth to get the pin all the way in place. Make sure it's all the way in, you don't want to strip the hole in the crank shaft.*!*
-To reduce risk of catastrophic engine failure, Change your water pump, thermostat, tension roller, idle roller, timing belt & second only to your water pump A NEW DAMPENER! Not changing a 10 year old dampener will lead to insufficient tension on the belt & opens the door to a plethora of possible problems.
- In order to achieve perfect timing you MUST pop the cam gears from the keyed ends. Its really not that serious & the "wings" are keyed onto the ends of the cams so they only go on one way. Buy a set of Cam Seals from a retail store. When you pop the Cam Gears, you'll have easy access to the seals. If you detect ANY oil at all around the seals, replace them. If not, just leave the current ones in place & return them when your done. Better safe than sorry.
THEN FOLLOW THESE STEPS
1. Replace water pump, thermostat, idle roller, tension roller (Cam seals if applicable) Dampener (leave pin in) & clean up the area in the rear timing cover.
2. Place the cam gears on the Cam Shaft Ends (loosely so they spin, but snug enough that they cannot move side to side), put the "wings" back onto their keyed location then hand tighten the Cam End Bolts, making sure the gears can spin freely.
3. Put Cam Lock Bar into position
4. Replace belt. Start belt around crank gear, over the idle roller, over the drivers side cam gear, under water pump, around passenger side cam gear then finally use some mechanic finger strength to push that bitch over the tension roller. When the gears can spin freely, there is no need to "stretch to the right tooth" tension gets distributed evenly across the entire belt (ding ding ding!)
5. Compress the dampener enough to pull the pin, once pin is pulled and dampener is exerting force on the belt, set your Torque Wrench to 15NM/11ft lbs/132 inch lbs, place an 8mm Allen on the wrench & torque the belt. It's hard to get it there & in some cases will not get there, but try as hard as you can without breaking your new belt.
6. Now Cam Gear Position is perfect, tension on the belt is even between all linkage! Now time to wrap it up! Pull out your Torque Wrench and a 16mm bit (*!*Must only be a 6 point*!*). Set wrench to 55NM/40.5ft-lbs/486 & a 1/4 turn inch lbs. Torque the Cam Shaft Bolts to spec & guess what... Your done & you did it right!
TIMING COVER REPLACEMENT
Save yourself the PITA and read this...
1. Thread Accessory Idle Pulley Bolts on LOOSELY
2. Place Lower cover (behind harmonic balance pulley) and loosely thread the two bolts.
3. Put drivers side cover on. Make sure the part that goes over the water pump is over the metal piece of the idle pulley, but the rest of the cover is under the pulley. Thread the bolts in hand tight.
4. Place center cover in its place, make sure at this point the "puzzle pieces" are fitting together how the Audi Gods intended, and snap the metal clamp fasteners in place. If the bottom fastener doesn't easily snap into place you need to reconfigure everything to fit properly.
5. Place passenger cover in it's rightful place and thread the long bolt in hand tight.
6. Check to make sure the "puzzle" lines up then tighten the accessory idle puller bolts (while making sure everything aligns). The design for these bolts baffles me. Pure stupidity Audi.... Then tighten the lower covers two 10mm bolts, and finish off with the rest of the T30's in a counter clockwise order.
7. Figure the rest out yourself! If you can't I don't know how you got this far!!!
Thread
Thread Starter
Forum
Replies
Last Post
fritz
Audi A4
2
08-12-2007 02:55 PM
