PLEASEREAD THEFOLLOWING BULLETINBEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT Bulletin: PreventPremature Water PumpFailure! BLAUfergnugen!Inc.recommendsthatan Audi VwFactory Trained ASECertified Technicianinstallyourparts toensureyoursafety. AlwaysreadRobertBentleyfactoryservicemanualsafetyinstructionsandguidelines. ALWAYS WEARSAFETY GLASSES ANDOTHERSAFETY ITEMS WHENPERFORMING THEFOLLOWING WORK! InstallersResponsibility: Blaupartsrecommendsthatinstallerstakethenecessarytimetothoroughlyfollowthestepsoutlinedinthisbulletintopreventfuturelabor costs,aswellasanyinconvenienceaftertheinstallationofthewaterpumpincludedinthistimingbeltkit.Ithasbeennotedthatduetotime constraints,inconvenience,andprofit,manyindividualsandmechanicsalike,donottaketheextratimeneededtothoroughlyflushtheentire vehiclecoolingsystempriortotheinstallationofthenewwaterpump.Justdrainingthecoolingsystemandrefillingthesystemisnotenough! Prematurewaterpumpfailure(waterpumpsealsandbearings)canoccurbecauseoffailingtotakethetimetoflushtheentirecoolingsystem anditsrelatedcomponents.Oftenwhenproblemsarise,suchasacoolantleak,thenewwaterpumpisblamedasthecausewheninfactthe oppositeistrue.Itisusuallybecausetheinstallerhasneglectedtofollowthesestepslistedbelow. FlushingtheCoolingSystem: Itisimperativethatthecoolingsystembethoroughlyflushedofallaccumulatedsiltandsedimentbuildup,includingallaftermarketcooling systemadditives,orstopleakproductsthatmayhavebeenaddedtothecoolingsystem,pastorpresent. Thiswouldentailflushingtheradiator, engineblock,heatercoreandhosesetc.UseOnlyTap Water toflushtheentirecoolingsystem.DONOT USECoolingSystemFlushProducts sincemanycontainmuriaticand/orotheracids.Remnantsofsuchacidsleftinthecoolingsystemcancauseyournewwaterpumpto prematurelyfail. Water PumpInstallation: Takeextratimeincleaningthewaterpumpgasket/o-ringmatingsurfaces.Makesurethesurfaceisfreeofalloldgasketmaterialandcorrosion buildupbeforeinstallingyournewwaterpump.Itmaybenecessarytousealightabrasivescuffpadorrazorblade.Gasketsealingagents shouldNOT beusedifyourwaterpumpincludesapapergasket.Ifthewaterpumpmountingsurfaceareaontheengineblockisthroughly cleaned,smoothandfreefromoldgasketdebris,gasketsealingagents(FormaGasket productsingelorsprayforms)arenotneeded.Sealing agentsvaryincompositionandintendedusage,andwhenusedinconjunctionwithpapergasketsmayaffectthepapergaskets’ longterm abilitytocompressand/orperformitssealingfunction. Appropriategellikegasketsealingagentsshouldonlybeusedinthecaseofsevere pittingoftheengineblocksurfacewherebyanevenandsmoothmountingsurfaceforthewaterpumpisnotattainable.Doublecheckallwater pumpmountingboltsfortightness. A looseormissingwaterpumporthermostathousingboltcanresultinaleakandfalselyattributingthe waterpumpasdefective. FillingtheCoolingSystem: IMPORTANT:Readthe Warningsontheantifreezecoolantbottle,improperuseisHARMFUL orFATAL.Useonly Audi, VwG-12antifreeze coolantwhichwasincludedinyourtimingbeltkit. Thesebottlescontaincoolantthatisconcentrated. Youmustdilutethecoolant.Mix50% coolantwith50%DEIONIZED WATER.DEIONIZED WATERISPREFERRED.However,ifitisnotavailableusedistilledwater.DONOT MIX TAP WATERwithnewcoolantifatallpossible. TapwatervariesinPhandmineralcontentanddependingonthesefactors,canadversely effectyournewwaterpumpandothercoolingsystemcomponents. Water PumpBreakinPeriod: Allwaterpumpsareinspectedandairpressuretestedatthefactoryforanyleaks.However,newwaterpumpsdohaveabreakinperiod.Itis notuncommonforanewwaterpumptohavesomeseepageofcoolantfromthedischargeholebelowthewaterpumppulleyshortlyafterstart up. Thisisbecausetheuniquesealmaterialinthenewwaterpumpisdesignedto‘bedin’ astheimpellershaftspins.Slightweepingor dampnessfromoraroundthedischargeholeorcapisallowableforatleast100milesafterinstallationandshouldnotbeattributedasa defectivewaterpump. Maintenance: MixingotherbrandsofunauthorizedantifreezecoolantswiththeapprovedG-12antifreezecoolantincludedinyournewtimingbeltkitcan alsocauseanadversechemicalreactiontoG-12coolant,causingthecoolanttogelandclot. Thiscandamagethenewwaterpump,plugthe coolingsystem,andweakenotherplasticcoolingsystemcomponentssuchas,theradiatorandplasticcoolanthoseconnections. Environment: Beenvironmentallyresponsible.Disposeoftheoldantifreezecoolantproperly. Page1Copyright© BLAUfergnügen!Inc.20129/14/12Form#Ins165/151 GuidelinesForInstallationOf YourVW TDIBEW (PD)TimingBeltKit AppliestoPartNumber:GH21121 !CAUTION! Performing Workon Your Automobile WithoutHavingProper Knowledge,Mechanical Ability or theProper ToolsandSafetyEquipment,CANCAUSESEVEREINJURY ORDEATH! BLAUfergnugen!Inc. recommendsyouhavean VolkswagenFactoryCertified A.S.E.Certified Technicianinstallyour partsto ensureyour safety. ALWAYS WEARSAFETY GLASSES ANDOTHERSAFETY ITEMS WHENPERFORMING THEFOLLOWING WORK ThefollowinginformationissimplyaguidelineandisnotintendedtoreplacetheofficialBentleyFactoryManual. Alwaysrefer tothefactorymanualfor proper installationandsafetyguidelines. 1) Positionthevehicleintheairusingacertifieldautomotiveliftandremovethepassengersidefrontwheel. 2) Removetheprotectivesplashpanusinga T-25 Torxdriver. 3) Removethelowerintercoolerpipebyremoving(1)10mmnutand(2)springclips,oneateachend. (Image1) 4) Loosenandremovethepassengersidefenderlinerbyremoving(2)pushclipsfromcorrespondingstuds. (Image2) 5) Loosenandremovethedecorativeenginecoverbyremoving(1)10mmfastenerattheaftofthecoverthenpull upward. (Image3) 6) Removeandorplaceallhosessuroundingtheupperintercoolerhoseofftotheside.Excludingthefuellines.(Image4) 7) Removeupperintercoolerhose.Releasespringclipatintakeandspringclipatintercoolerjustbellowtheheadlight. Sometimesitisbesttounplugtheheadlightplugsandorsuroundingcomponentsinareainordertoreleasethespringclip attheintercooler.Removebypullingintakeendoffandthentheintercoolerend.Nextpullupwardinthedirectionofthe windshield. (Image5and6) BLAUfergnugen!Inc-BLAUfergnugen!Inc-BLAUfergnugen!Inc Image1 Image2 Image3 Image4 Image5 Image6 Page2Copyright© BLAUfergnügen!Inc.2008Form#Ins151 GuidelinesForInstallationOf YourVW TDIBEW (PD)TimingBeltKit continued......... BLAUfergnugen!Inc-BLAUfergnugen!Inc-BLAUfergnugen!Inc Image7 Image8 Image9 8) Drainthecoolantfromtheenginebyremovingthelowerhosefromtheoilcooler, (Image7) thendraintheradiatorattheradiatordrainknoblocatedonthelowerdriverssideoftheradiator. (Image8) 9) Useaphillipsscrewdriver,remove(2)screwssecuringthecoolanttank.Removebothhosesconnectedtothe coolanttankandlocatethemtothesideaswellremovethelevelsensorplug.. 10) Usea5mmallenwrench,removethesingleallenheadboltthatsecuresthepowersteeringreservoirtothemotor mount. Asanoption,youcanchoosetocompletelydrainthepowersteeringsystemandremovebothpowersteering hosesandreservoirforeasieraccesstothearea.(Refillusing ApprovedG002000SteeringFluid-seeBlauparts.com) 11) Usinga16mmopenendwrenchrotatetheserpentinebelttensionerinaclockwisedirectionandremovethebelt. (Image9) 12) Usinga13mmsocket,remove(3)boltsthatsecuretheserpentinebelttensioner totheengine. (Image9) 13) Removeuppertimingbeltcoverbyreleasing(2)clipsandthenpullupwardonthecover. (Image10) 14) Removetheplasticcoveronthevibrationdamperpulleythenremove(4)6mmallenheadboltsthenremovethepulley. Note: Tocounterholdthecrankshaftusea1/2“driverachetand19mmsocket.(Image11) TorqueSpec-14ftlbs 15)Removethelowertimingbeltcoverbyremoving(5)10mmbolts.(uppermostboltnotpictured) -Important: ApplyLoctitetotheseboltswhenreinstallingthecover. (Image12) BLAUfergnugen!Inc-BLAUfergnugen!Inc-BLAUfergnugen!Inc BLAUfergnugen!Inc-BLAUfergnugen!Inc-BLAUfergnugen!Inc Image10 Image11 Image12 Page3Copyright© BLAUfergnügen!Inc.2008Form#Ins151 GuidelinesForInstallationOf YourVW TDIBEW (PD)TimingBeltKit continued......... 16) Ifthecrankshaftsealisshowingsignsofleakagereplacethesealasfollows:(Ifthesealisbonedryyoumaywhich toleaveitalone.)A) Positiontool3099inthelowercranktoothedpulleythenloosenthe12point19mmcrankbolt. Note:Makesureyoufullythreadinthe3099securingboltsintothetoothedsprocket. (Image13)Note: Donotremovetheboltortoothedpulleyatthistime. 17) Supportenginewithapprovedenginesupport.(Image14) Warning:Failuretouseaappropriateandsafetyapproved enginesupportcouldresultinInjuryorDeath. TimingBeltRemoval: 18) Usea1/2“driverachettoremove(2)18mmmotormountboltsfromenginebrackettobodymotormountbracket. (Image15) 19) Usea1/2“driverachettoremove(2)16mmbodymotormountboltsandremovebodymotormount. 20) Removethecastmotormountbracketsecuredtotheenginebyremoving(2)16mmboltsonthetopsideandthen(1) 16mmboltonthebottomsideofthebracket.(Image16)-Note: Insomecasesyoumighthavetoraisethepassengers sideoftheenginetobetteraccessthemotormountbracketfasteners. 21) Raisedriverssideofenginetoremovemotormountbracket.(Image17)-Note: Thiscanbedifficult.Makesureall fastenershavebeenfullyremovedfromthebracketsotheyarenotintheway.Liftbracketupandthenforwardtoward frontofcar. Youmayhavetolightlypullonthea/cevaporatorpipetoallowthemotormountbrackettoclear.Ifyouare unabletoremovethebrackettowardsthefront,youwillneedtoremovetheturboairintakepipeinordertoremovethe motormountbymovingittowardstherearofthevehicle. BLAUfergnugen!Inc-BLAUfergnugen!Inc-BLAUfergnugen!Inc BLAUfergnugen!Inc-BLAUfergnugen!Inc-BLAUfergnugen!Inc Image13 Image14 Image15 BLAUfergnugen!Inc-BLAUfergnugen!Inc-BLAUfergnugen!Inc BLAUfergnugen!Inc-BLAUfergnugen!Inc-BLAUfergnugen!Inc Image16 Image17 Page4Copyright© BLAUfergnügen!Inc.2008Form#Ins151 GuidelinesForInstallationOf YourVW TDIBEW (PD)TimingBeltKit continued......... 18) Rotateengineclockwiseuntilenginetimingmarksalign.Ifoneofthetimingmarksdonotalignrotatetheengine anotherrevolutionandcheckyourtimingmarksagain. Thecrankshafttimingmarkshouldalignwiththemachinedhole