2.7T Timing Belt, Waterpump, Thermostat DIY, no lock bar.

[PluschakovP]

This is done on my 2002 A6 6 Spd 87k Miles, with ECSTuning's Ultimate Timing belt kit. Link below. Overall the kit is everything you need to do the job. I love the waterpump, it's heavy duty. The gasket that came with the waterpump is a soft material, but the OEM one I took off was metal, so I was kind of bummed that they didn't include a metal gasket, ( in 100k miles, I'll be using a razor blade to get the gasket off when I redo it all again :\ ) The Thermostat is "Made in China", so that I did not like. The belts are from ContiTech, and the rollers, well just rollers heh... I also bought a new tensioner, grenade as I call it.

http://www.ecstuning.com/Audi-C5_A6-...lt_Kit/ES2576/

In total, it took me 5.5 hours, start to finish. Would've taken less, but I'm still happy.

Just the bumper off.


Radiator support taken off.


BiPipes off.


Fan blade off.


Take loosen the power steering pump pulley while the accessory drive belt is still on, it's easiest this way.


Now take off the accessory drive belt.


Line up the Crank to TDC (Top Dead Center), at this point. It's a 1" star socket.


Now, take off the timing covers.


... And mark the cam pulleys with white out, so you know the crank TDC and these marks are aligned. (Do both cam pulleys)


Take power steering pulley off.


Take the accessory drive belt tensioner off.



Now, this for me was the hardest part of the entire service, taking the fan clutch off. I did it this way, it may not be right, but it was effective for me.

Put a screw driver in here like so.


And use vice crips like so, and turn RIGHT. The fan clutch loosens to the Right, not left like normal things.


Here it is, fan clutch off.


Now there are 2 bolts you need to loosen that are inside this pulley system the fan clutch attaches too. I forget the size, but they are a PITA if you don't have long torx bits.
Here's 1.


And 2.


Fan clutch assembly off.


Make sure the Crank is TDC, then remove the crank pulley.


Then remove the cover behind the crank pulley, (2 bolts only)


Now with the markings on the cams, and the crank in TDC, take off the timing belt tensioner (the grenade, bottom left).


Next, the brass hook that's right by the grenade and the tensioner pulley.


You may now remove the timing belt.


Remove the idler pulley (bottom right).


Now loosen all the bolts to the waterpump. (Remember there is one behind the power steering pump)


Bolt behind power steering pump.


Loosen this bolt, and the 4 bracket bolts that hold the Power steering pump in place. Lift it, and remove the 1 last waterpump bolt.


Take the waterpump off.


Clean the surface along the edges, and then install the new water pump. Don't strip the bolts, they're weak...


Tighten/Bolt down the power steering pump now.

[PluschakovP]

Now the waterpump is done, take off the thermostat housing. only 3 bolts.


Take the thermostat out.


Clean it up a bit, and install the new thermostat. The O Ring needs to be on the housing side, NOT inside the block.

New Thermostat and Waterpump installed.


New idler roller, tensioner installed, with the brass hook thingy...


Now...
Make sure your cam pulleys are lined up properly to your previous marks.
Put on the crankshaft plastic cover on (2 bolts).
Then put on the crankshaft pulley.
Make sure it's at TDC still.

Take off the crank pulley and plastic cover. Make sure everything is aligned properly.

Once it is all aligned, put the belt on. It's a little tight, but make sure you don't spin the pulleys during this step.


Put your tensioner grenade on, but DO NOT pull the pin yet.

NOW.... squeeze the timing belt on the left just above the grenade with one hand, both above the cam pulley and below so as to give the belt some tension.

Take your 1" socket and rotate the timing belt several times. I mean 5-10 full rotations. Make sure each time that when the crank is at TDC, that your cam pulleys line up perfectly with your markings that you made. 1 tooth off and you'll have a check engine light.

So, now that you have rotated the engine 5-10 times, and each time it all lines up perfectly, PULL THE GRENADE.

You'll now have tension on the belt, so let go of it with your hand, and rotate the engine another 5-10 time, again make sure each time the crank is TDC, your cam pulleys are lined up perfectly too.

Now put everything back together.


And here are the things that are left of the mess.



Click the video below.

[Gumby]

link to original thread: http://www.audizine.com/forum/showth...IY-no-lock-bar.