4kq still broken, help please

["Gregory C Mayer, Hydrologist, GW Spec, Atlanta, GA "<gcmayer@usgs.gov>]

Hello Audi Fans,
Thanks for all the replies about the thermoswitch in my '84 4000S
quattro (2.22l 5 cyl.).  I found it and replaced it.  In the mean time
the water pump let go so I started on it.  Got it out fine and now have
several problems; 

1) what size socket fits the crank bolt the holds the acccessory
pulleys and timing belt gear on?  It is smaller than 30 mm but not by
much. What size do I need here, 28mm?  I see that it is on very
tight and expect it to be tough to remove.  I need to remove it to
replace the timing belt, which is very accessible now and worn.   Also,
will having someone hold the brake pedal down, with the transmission in
gear be enough to keep the crank/engine from turning?   Any tips here
would be greatly appreciated.

2) with the engine at TDC ("0" on flywheel alinged with casting index
flange in hole) the cam timing belt gear does not seem to be alinged
properly.  The little punch mark hole on the gear tooth does not line
up with the head/valve cover seam, but is almost 30 degrees behind,
just about straight up. I checked it several times.  Also, I'm pretty
sure about the punch marked hole and found no other marks on either
side on the gear?  I marked the postion of the valve cover/head seam
before disassembling.  Yes, the engine ran very well in this position.
This position placed the woodruf key at almost straight down on the
bottom of the camshaft.  Is this possibly correct or there something
weird here?

3) the idler pulley seems to be fine, put since I'm there should it be
replaced?  How is it removed/installed.  With the thin bolt out, the
pulley seems to be still very much in place.  

Thanks again for your time and information.  This is one hell of a great
group.  

Greg