ABY Timing Belt Renewal

[volcano rs]

I made it, not sure if you can buy such a tool...

Its been borrowed on many occasion no bent cranks yet!! you wouldn't bend a cast crank with a spanner how ever large. It would shatter before it bent and none have yet...

If you lighten your front pulley... enough... or use an aluminium one you have no choice..

i have a alloy pully i wouldn't mind seeing that tool to make one for my self if you don't mind mr jones .and i doubt you would bend the crank ,its one tough piece

[DJones]

i have a alloy pully i wouldn't mind seeing that tool to make one for my self if you don't mind mr jones .and i doubt you would bend the crank ,its one tough piece

No problem, pm me your address and i will post it to you for you to copy.

I agree on the crank too and to prove it andy_casey borrowed it last which was before Christmas and given the luck he was having at the time if any ones crank was going to bend snap whatever it would have been his...

[volcano rs]

No problem, pm me your address and i will post it to you for you to copy.

I agree on the crank too and to prove it andy_casey borrowed it last which was before Christmas and given the luck he was having at the time if any ones crank was going to bend snap whatever it would have been his...

the engine in my shorty came out of a s2 which had been hit at the front . front pully the crank sprocket were all smashed and the engine had been pushed back by the impact the gearbox mountings were also broken ,i rebuilt that same engine had the crank checked by machine shop there was no damage to it at all .and mr jones you have a pm thank you

[S2 Ant]

That picture highlights what i mean perfectly Mcandmar!
It looks like it needs another 10mm or so to reach that threaded part and the block next to it so the flat edge locks up to it.
From memory the distance its short by is about the width of one of the pulleys as there are 3 belts run there - probably not the case but just the first thing that came to my mind when i saw it

[S2central.net]

Good pic Mark... But I've annotated some questions here - do I understand correctly that you need remove the snub mount & ac bracket to get to that bolt hole ?

If so, a modified 2084 tool is much less hassle IMO.


Paul

[mcandmar]

The bolt goes the other way around, bolt head is on the face of the locking tool and threads into the block.

Can’t remember what the issue was with the snub mount, i took it off so must have been in the way.

I managed to get the pulley off with some improvisation but would like to know how’s its supposed to be done

[S2central.net]

As an aside from the cranklock tool banter for now ---> While I have the info in front of me, heres the list of parts I used for the job. Note this was for ABY engined S2 - I could have gone for faster spinning RS2 water pump and belt, but figured no need...

054 109 119H - toothed timing belt
054 109 479A - tensioner bracket and idle pulley
054 121 004AV - new water pump, comes with O-ring
034 105 263A - crankshaft pulley (in case original was cracked - it wasnt)
034 105 229A - main pulley bolt (big one)

N 014 726 3 - allen headed bolts for crank pulley (4-off)
N 014 716 2 - allen headed bolt at water pump (clamps PAS pump adjuster too)
N 011 670 16 - washer for above
N 010 247 8 - M8 bolt for water pump (2-off)
N 012 241 10 - washers for above (2-off)
N 010 218 6 - M6 x 25 bolts for tensioner (3-off)
N 011 524 23 - washers for above (3-off)

EDIT - The only part I did not renew was the large spacing washer that is sandwiched between the crank pulley and the toothed sprocket. That is part number 034 105 193 on the ABY and retails for a whopping £20 - quite some washer you'd think but I do recall reading in the manual that it is somehow diamond coated which might explain that. OFRM does NOT state this need be replaced but that it should be cleaned of any grease before fitment...

Important torque values to added here for the records here too.


Paul

[S2central.net]

Oh the other belt part numbers first...

034 260 849 E - PAS v-belt is closest to engine
034 260 849 - Aircon v-belt next (mine is 1994 R134a with Zexel compressor)
034 903 137B - Alternator ribbed belt

Paul

[S2central.net]

Torque values (in no particular order) as follows - placeholder for info here - I'll get round to a nice write up with photos and stuff as time permits (famous last words)

Water pump bolts - 20Nm for the little allen bolt. 25Nm for the 2 x M8 bolts

Tensioner bolts - 20Nm (thats twenty - not 29 like the typo in the manual !!!)

Crank pulley allen bolts - older manual calls up 25Nm. Later manual states 20Nm plus 90 degrees. My torque wrench doesn't go lower that 30Nm, so I carefully went for 35Nm (thirtyfive) just in case.

Main pulley bolt (the big one with some threadlock on 1st) is 200Nm plus 180 degrees

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

[ericd]

Oh the other belt part numbers first...

034 260 849 E - PAS v-belt is closest to engine
034 260 849 - Aircon v-belt next (mine is 1994 R134a with Zexel compressor)
034 903 137B - Alternator ribbed belt

Paul

Ordered the same parts during the week, timing belt and others done, due to hall sender failure, 4.2 hrs allocated time at Audi dealer.

[ericd]

Oh, forgot to mention , car still had original timing and ancillary belts on it (12-13 years) , all looked in decent condition though once removed.

[S2central.net]

Sorry for the delay on the full 'how to' but here it finally is --->

http://s2central.net/Timing_Belt_Renewal_Rev1.pdf

Please do let me have any constructive feedback on how this could be improved, clarified or simplified in any way.

I hope its useful to someone other than me the next time I have to do one

Paul

[Knight Rider S4]

Fantastic write up Paul and pics ..The only thing i would of done as well is replace the crankshaft seal just for peace of mind

[S-Express]

Fantastic write up Paul.
With all your S2 knowledge you have amassed - why don't you compile it all and sell it as a workshop manual on CD!?

[missmouse]

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?

Simon