TRAGEDY AVERTED!! (was: Workin' on the Coupe -- finished workin'!!)

[Ken <kkeith@qnet.com>]

Below is a message I began typing in response to Eric, but I'm going to
copy the list and a few others as well. I was originally too tired to
type anything up regarding my weekend project, but since I've already
typed so much, I'll share it with the list.

Thanks to all who contributed to my project.  Everyone's help is greatly
appreciated.  It could have been a painful lesson.

As you read what happened, keep in mind that:

1)  I am not an idiot, and 
2)  It was my first time doing this much work (on an Audi, anyway)

Fluhr wrote:
> 
> > A long time ago you told me about when you changed your lifters <above>.  Do you remember how you got the 
> > cam gear bolt off?  I can't seem to get mine off.
> 
> Are you talking about the single large bolt that holds the cam sprocket
> onto the end of the camshaft?  I just stick a wrench on it and take it
> right off.  The timing belt holds the gear/camshaft in place.

I got it off.  I was told the belt would jump a tooth or two if I did
that.  It happened to another lister, bent his valves, costing mucho
$$$.  I ended up using a pair of Vice Grips on the sprocket itself,
sideways.  This held against the core support while I remove the bolt. 
I was surprised at how easily that bolt (and all of them, really) came
out.  This was my first extensive use of a torque wrench, and I've
discovered that I have always massively over-torqued anything I was
tightening in the past.  I was almost afraid to trust the torque wrench,
because it seemed like nothing was very tight when using the Bentley's
specs, but I did go with the proper settings.

Finished the whole job over the weekend.  Believe it or not, I had to
take the thing apart at least three separate times!  The first time, I
forgot to put the o-ring on the water pump.  Had it all buttoned up and
everything, grill, bumper and all, and the water pump was leaking.  Went
for a drive to test it out.)  I wasn't gonna pull it all apart right
away, I was tired of working on it.)  Drove great, more power, seemed to
breath better.  It revved freely, and built power to redline instead of
running out of breath.

Next day, took it all apart, took the cam sprocket off (instead of the
belt), found that the water pump o-ring was missing, and then checked
the box the pump came in.  There it was!  I must have been too concerned
with getting the cam timing straight, the pump was an afterthought.

Then, I button everything up again, fire it up, and back it out of the
garage.  Then I notice a little "key" on the floor.  Not key as in for a
lock, but key as in "just like the one that's supposed to be in the end
of the cam, inside of the sprocket"!  Methinks to myself, "Hmmm, my cam
didn't come with a new one of those, and it's certainly not "extra". 
Uh-oh."  So, I FIRE IT UP AGAIN, and drive it back into the garage. 
(yes, I know, VERY risky, but I was too tired to push it back in)

PULL IT APART AGAIN, and sure enough, no freakin' key in the end!  Holy
sh*t!  Turns out that when I put it on last time, it was difficult to
get on, as if the cam had rotated due to resting directly on a lobe or
something.  In my struggles to get the gear on, I must have pushed the
key out instead of getting it in the slot.  Coulda been really bad!

So, I put the key in, and button it all up a second time.  Later on, I
take it for a drive, and it acts really wierd.  No power at all at low
to mid RPM's.  Since I already drove it w/the cam by this time, and it
was much different, I immediately suspect improper cam timing.

I put the crank at TDC, and check the cam timing mark.  Turns out to be
a coupla teeth over too many, so ONCE MORE, I pull it apart, and fix
it.  The timing belt was a little tight after the second reassembly
anyway, so I got to fix that.

Everything is now together and working beautifully.  Drove it to work
today (about 40 miles one way).  The extra power comes in handy, as does
knowing that my timing belt is new.

My gosh!  I am so exhausted.  My whole 5 day weekend was used up to get
this done.  I replaced my strut housings, cam, lifters, water pump,
timing belt, and valve cover gasket.  Last weekend, I did my A/C hose,
all radiator hoses, radiator, thermostat, thermostat and fan switch
gaskets, and got the A/C charged.

Maybe next weekend, I'll try to do the clutch and rear engine/tranny
mount, and reverse light switch.

Sheesh!  My hands hurt!

Sincerely,

Ken
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