79 replies to this topic

[flash]

i will be clear of all of my other projects immediately following the superbowl. my car will be up in the air due to the splitter work, so i will then be reviewing the footage, completing my notes, and publishing the DIY.

sorry guys. this had to get knocked way down on my list.

[DaveN]

Who cares, I have 2 years left on my belts . I'm more pumped on the "due to the splitter work "!

[Big Carl]

Now that the splitters are shipping (they look amazing btw) is the focus going to come around to the DIY?
I pushed my luck last summer and ran on 4 year old belts. Im smart enough to know not to go for 5.
Is there any way around using the tension tool, or will I need to locate one before I can attempt this?

[flash]

trying to get to it. still dealing with splitters, and of course my own engine, but i think i can get to it. i pulled together the files, and am compiling stuff

[kzem1]

Looking forward to the DIY Flash! I have 2 cars still to do after comleting 1 belt job with my friend Josh, holding my hand, so to speak. It would be great to have that DIY on hand when I go to tackle the other 2 cars on my own.

Kevin

[flash]

the 4 hours of video is what's holding me up. i just haven't been able to dedicate the time to set up and review that, take notes, capture shots i failed to take with the camera, and then put it all together.

but i'm trying. i put myself in this position by tackling and engine build, splitter project, and 2 other new parts development projects, all while trying to fulfill other orders of existing stuff (i'm out of almost everything AGAIN), as well as dealing with a new puppy (who just got spayed 2 days ago, is up to 80lbs now, and is a pain in the butt). then there is the real job that keeps getting in the way of my car stuff

but i'm trying

[Monstrous4Banger]

Yeah I need to do my 86', and 93' soon. Eagerly awaiting a fully comprehensive DIY.

[rxter]

An 80 lb puppy?? What kind of dog is that (and don't answer a big one)?

[flash]

another bernese. 8 months now. she'll be 90-95 when full grown. already bigger than the 8 year old though.

[AJG]

With all that's going on for you Bob it's just as well that breathing is an involuntary action!

[flash]

lol - true enough. i spent the entire day today just cleaning up in the garage and getting ready for projects. lots of stuff going on this week and next as i wrap up the engine build and get ready for detail day. it was good though to really have the time to get organized. it happened by accident because i didn't make it to the mailroom before it closed to get the stuff that came in for a new project. that will have to wait until tomorrow. no worries though.

[flash]

i'm actually getting a bit closer to doing this. i've started to sort through the materials.

on another note, i see more incorrect information being bandied about on another site. no shock there though. for the record, the OEM belt currently supplied from porsche, in the porsche box, is the GATES belt. i just bought them.

[robbgerard]

Hey Flash, I was just wondering if you are still working on the belt DIY?

Thanks!

[flash]

i haven't worked on it in quite a while. i've been way too busy developing stage 2 and 3 of the supercharger kit, filling orders, and spooling down production on everything else.

[marazas]

Hi! Would be a nice and wanted material when it is ready. Still waiting

[Blau]

What are the chances of this video ever surfacing?  My car is due for it's belt change this winter and while I can follow instructions and photos...video is always a better help!

Even just putting up the raw video could help...

[Cloud9...68]

There are several of us who have done this job recently, including myself, Bulti, and PorscheG96, and while none of us, as far as I know, has created a video, we'd all be more than happy to answer any questions you may have.  A few weeks ago, I posted a summary of what I found to be the most critical steps of the procedure, and how I handled them.  You might want to start by doing a search for it.  Good luck.

[Husky1]

I searched for summary but could not find it. What am I doing wrong?

 

Thanks Jeff

[Cloud9...68]

Here's the summary I put together of some of the key things to look out for when changing the belts:

 

I just finished my belt change a few days ago. Here are a few pointers to help make the job go more smoothly:

1. Go ahead and unplug the fan motor connectors, and remove the fan. This will give you a lot more room to work.

2. To set the engine at TDC in cylinder No. 1, remove the rubber cap on top of the distributor, then rotate the engine clockwise by hand until the mark on the camshaft sprocket lines up with the notch in the back belt assembly cover. Then, go to the back of the engine, and on the drivers side, look for the opening in the top of the bell housing. There should be a mark on the flywheel that is visible. If you car doesn't have the window on the distributor, I would go ahead and remove the distributor now, since you're going to have to do that anyway, to ensure that you're at TDC. The rotor should be pointing at about 11:00 oclock, iirc, at TDC.

3. With the engine at TDC, the "O" that's stamped on the upper balance shaft belt sprocket that's peeking through the oval-shaped hole in the cover should be on the top half of the pulley. Then, get a mirror and look at the bottom half of the lower BS sprocket. The "O" on that sprocket should be peeking through a rectangular opening on the bottom half of the sprocket. And of course, the indents in both sprockets should be pointing directly at their respective marks in the plastic housing behind the belt assembly.

4. To remove the timing belt, you have to remove the tensioner. To do this, you have to remove the chrome-plated guide that sits along the bottom of the belt, which is held in by four M6 bolts. You also have to loosen (but not necessarly completely remove) the few bolts in the vicinity of the tensioner that hold the plastic back cover for the belt assembly. Doing this will allow you to pull this cover foreward, which will allow you to maneuver the tensioner out.

5. When installing the timing belt, it should be pretty tight on its upper run, which extends uninterrupted between the camshaft sprocket and the crankshaft sprocket. With the belt positioned correctly, you should count 48 belt teeth between the cog on the camshaft sprocket that sits immediately to the right of the mark on the cam sprocket, and the cog on the crankshaft sprocket that sits immediately outboard of the "105" part number that's stamped in the crankshaft sprocket. In order to get this to happen, you will likely have to slightly rotate the camshaft sprocket clockwise, just enough to move the belt over by one tooth relative to where it want to naturally lay. You will have to overcome to retaining force of the valve springs to do this, and the sprocket will snap back into place after you're moved the belt over. Bulti told me he used a tool he had fabricated to hold the pullies in place while he was turning the M10 bots that hold them in place. I fabricated a tool from some hardware I had used earlier for a different purpose. You may have to get creative, but you will need to figure out some way to rotate the cam sprocket enough to move the belt over by one tooth relative to how it wants to sit if you just lay it in place, as this will leave too much slack in the belt, and will throw your cam timing off. For me, this was the trickiest part of the job - thanks to Bulti for explaining the need to rotate the cam sprocket, and to Porsche96G for confiming the 48-tooth count.

6. Remember that when setting the balance shaft belt tightness and clearance between the bottom of the idler pulley and the pulley below, that the spec for the location of the top of the idler pulley relative to the BS belt is a deflection, not a clearance. It calls for a 0.1 mm deflection, which is way to small to measure accurately. Just make sure the BS belt is slightly in contact with the top of the idler pulley.

The rest of the steps are pretty straightforward. Good luck with the job, and post or IM if you have any questions. 

[P38Light]

Cloud9,

 

Just want to be sure about the 48 belt teeth before I button this up. The count begins on the belt tooth immediately to the rioght of the mark on cam sprocket and ends with the belt tooth radially outside of the "1" in "105", or is it the tooth outside of the "5"? My crank sprocket appears to have the "0" in "105" radially inside the cog, so belt teeth straddle the "0", giving me two places to start counting. With the new belt installed and tensioned, I have 48 belt teeth from the "1" in "105" to the tooth immediately to the right of the cam sprocket mark. Hopefully I'm there.

 

Thanks,

P38Light