ABY Timing Belt Renewal

[kwlw]

did I read on another thread someone worked out how to get 450Nm by using their body weight plus a known length of extension bar to the pulley bolt?
Like, I weigh 85kg so how long a bar would I need to acheive this torque?

I'm not good @ physics, however I guess, that 450Nm is 450N at 1m radius, so you need approx 45kg of force at 1m length bar. Or your weight at something around half of that (both feet up in the air) .

I may be wrong . But I torque CV nuts (typ85) with one of my legs on 1m bar (~35kg), and they are tightened pretty well so far (tested successfully more than 20 times).

And about "calibration" - you can use bathroom scales, to calibrate your force (actually did that for brake pedal force measurement ).

Sau

[Fat Audi 80]

I'm not good @ physics, however I guess, that 450Nm is 450N at 1m radius, so you need approx 45kg of force at 1m length bar. Or your weight at something around half of that (both feet up in the air) .

I may be wrong . But I torque CV nuts (typ85) with one of my legs on 1m bar (~35kg), and they are tightened pretty well so far (tested successfully more than 20 times).

And about "calibration" - you can use bathroom scales, to calibrate your force (actually did that for brake pedal force measurement ).

Sau

Correct. 1kg @ 1m radius = 10 Nm....

[Graham]

Put the reaction bar onto an axle stand and not the snub mount as long as it is long enough then all the force goes into the bolt then onto the floor and your mounts remain unstressed, and nothing vital is damaged.
Graham

[S2central.net]

Thats a good tip for REMOVAL of the big bolt !

[wilywyg]

crank pulley removal

Can see why bars like this are used

I been trying now 2 days to get the crank pulley off with no sucess .I have broken the tool from audi vag 3256. Then i made my own up with a long handle and a large socket with a slot cut out .and used the ground to pull on. broke my socket then whent and got a impact set then the wrench handle broke. so got a (for life set) that broke with a 1.5 mrt bar on it .Ive put heat onit , left it over night with goo. I was jumping up and down on it .im not a small chap(f95kg)what is the bolt made from, I can not move this thing at all ,can i borrow these please or has anyone got any good ideas.i will be willing to tavel a few miles to say the least to get this sorted.

cheers
Paul

[valjo]

Finally - the timing belt needs to be tensioned such that it can just be twisted thru 90 degrees in the section above the water pump. Hand crank the engine a few times and double check the tension and timing marks are in alignment.

Paul

I will also change timing belt on my s2 very shortly. Questation is if you test belt tension on cold or hot engine ?

valjo

[Flat on my back]

.

Doesn't make any difference to the belt.

[johne]

I will also change timing belt on my s2 very shortly. Questation is if you test belt tension on cold or hot engine ?

valjo

Cold engine.

John

[valjo]

Cold engine.

John

That is right! I read carefully factory manual again yesterday and engine MUST be cold.

[macspring]

Paul,

This link might be of use?

http://www.audiworld.com/tech/eng103.shtml

Kind regards.

[chezz]

Its a bit naff the way the vibration damper is attached to the crank with that big bolt... The pulleys behind it just have the 4 x M6 bolts to hold them - if the damper just used those then there would be no need to remove that bottom bolt for timing belt renewal. I've seen other crank/pulleys that do it that way. I might consider a modification to the vibration damper for such a tweak - dunno yet. ?

Paul

Hell of a lot of rotaing mass there...cant see four puny allen bolts taking the strain for long!

[bad8008]

Read the instructions on the Timing Belt Renewal.
Great write up.

Whats the updated part number on the Toothed Belt for the ADU engine? Can the same belt as the ABY engine be used on the ADU?
What aftermarket brand is accessible, Contitech?

[TimE-J]

Anyone know where I can get this locking tool from?

[terrybullwon]

Nope but i have a very crued one here that will lock the fly wheel dead from the starter mount

Then you just need a ****ing big torque wrench

[TimE-J]

Any chance you would be able to get picture of it, just curious, my belt doesnt need doing it was done by me 12months before I bought the car in my work and Ive got to be honest I didnt use any locking tools...

I will invest in a genuine locking tool at some point, but I also like making my own tools.
After looking through a few catalogues Ive noticed that the VW T4 Transporter 2.5 I5 TDI crank tool looks very similar.