PLEASE READ THE FOLLOWING BULLETIN BEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT

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PLEASE READ THE FOLLOWING BULLETIN BEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT Bulletin: Prevent Premature Water Pump Failure! BLAUfergnugen! Inc.

ALWAYS WEAR SAFETY GLASSES AND OTHER SAFETY ITEMS WHEN PERFORMING THE FOLLOWING WORK!

1 PLEASE READ THE FOLLOWING BULLETIN BEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT Bulletin: Prevent Premature Water Pump Failure! BLAUfergnugen! Inc. recommends that an Audi Vw Factory Trained ASE Certified Technician install your parts to ensure your safety. Always read the factory service manual safety instructions and guidelines. ALWAYS WEAR SAFETY GLASSES AND OTHER SAFETY ITEMS WHEN PERFORMING THE FOLLOWING WORK! Installers Responsibility: Blauparts recommends that installers take the necessary time to thoroughly follow the steps outlined in this bulletin to prevent future labor costs, as well as any inconvenience after the installation of the water pump included in this timing belt kit. It has been noted that due to time constraints, inconvenience, and profit, many individuals and mechanics alike, do not take the extra time needed to thoroughly flush the entire vehicle cooling system prior to the installation of the new water pump. Just draining the cooling system and refilling the system is not enough! Premature water pump failure (water pump seals and bearings) can occur because of failing to take the time to flush the entire cooling system and its related components. Often when problems arise, such as a coolant leak, the new water pump is blamed as the cause when in fact the opposite is true. It is usually because the installer has neglected to follow these steps listed below. Flushing the Cooling System: It is imperative that the cooling system be thoroughly flushed of all accumulated silt and sediment build up, including all aftermarket cooling system additives, or stop leak products that may have been added to the cooling system, past or present. This would entail flushing the radiator, engine block, heater core and hoses etc. Use Only Tap Water to flush the entire cooling system. DO NOT USE Cooling System Flush Products since many contain muriatic and/or other acids. Remnants of such acids left in the cooling system can cause your new water pump to prematurely fail. Water Pump Installation: Take extra time in cleaning the water pump gasket/o-ring mating surfaces. Make sure the surface is free of all old gasket material and corrosion build up before installing your new water pump. It may be necessary to use a light abrasive scuff pad or razor blade. Gasket sealing agents should NOT be used if your water pump includes a paper gasket. If the water pump mounting surface area on the engine block is throughly cleaned, smooth and free from old gasket debris, gasket sealing agents ( Form a Gasket products in gel or spray forms) are not needed. Sealing agents vary in composition and intended usage, and when used in conjunction with paper gaskets may affect the paper gaskets long term ability to compress and/or perform its sealing function. Appropriate gel like gasket sealing agents should only be used in the case of severe pitting of the engine block surface whereby an even and smooth mounting surface for the water pump is not attainable. Double check all water pump mounting bolts for tightness. A loose or missing water pump or thermostat housing bolt can result in a leak and falsely attributing the water pump as defective. Filling the Cooling System: IMPORTANT: Read the Warnings on the antifreeze coolant bottle, improper use is HARMFUL or FATAL. Use only Audi, Vw G-12 antifreeze coolant which was included in your timing belt kit. These bottles contain coolant that is concentrated. You must dilute the coolant. Mix 50% coolant with 50% DEIONIZED WATER. DEIONIZED WATER IS PREFERRED. However, if it is not available use distilled water. DO NOT MIX TAP WATER with new coolant if at all possible. Tap water varies in Ph and mineral content and depending on these factors, can adversely effect your new water pump and other cooling system components. Water Pump Break in Period: All water pumps are inspected and air pressure tested at the factory for any leaks. However, new water pumps do have a break in period. It is not uncommon for a new water pump to have some seepage of coolant from the discharge hole below the water pump pulley shortly after start up. This is because the unique seal material in the new water pump is designed to bed in as the impeller shaft spins. Slight weeping or dampness from or around the discharge hole or cap is allowable for at least 100 miles after installation and should not be attributed as a defective water pump. Maintenance: Mixing other brands of unauthorized antifreeze coolants with the approved G-12 antifreeze coolant included in your new timing belt kit can also cause an adverse chemical reaction to G-12 coolant, causing the coolant to gel and clot. This can damage the new water pump, plug the cooling system, and weaken other plastic cooling system components such as, the radiator and plastic coolant hose connections. Environment: Be environmentally responsible. Dispose of the old anti freeze coolant properly. Page 1 Copyright BLAUfergnügen! Inc /14/12 Form # Ins 165/145

Guidelines For Installation Of Your Audi 1.8T AEB, ATW Timing Belt Kit Applies to Part Number : GH21102, GH21102-1! CAUTION!

recommends you have an A.S.E. Certified Technician install your parts to ensure your safety.

Always refer to the factory manual for proper installation and safety guidelines. 1) After following and completing the bumper cover removal guidelines, remove all decorative engine covers.

3) Remove the turbocharger coolant and vacuum hoses that run in front of the timing belt cover. Place these off to the side.

5) Use an 8mm allen head socket wrench along with special tool # 3212 to remove the viscous fan.

7) If applicable (AEB Engine Code models), remove the water pump v-belt and the (3) fasteners holding the 2 piece water pump pulley in place.

2 Guidelines For Installation Of Your Audi 1.8T AEB, ATW Timing Belt Kit Applies to Part Number : GH21102, GH ! CAUTION! Performing Work on Your Automobile Without Having Proper Knowledge, Mechanical Ability or the Proper Tools and Safety Equipment, CAN CAUSE SEVERE INJURY OR DEATH! BLAUfergnugen! Inc. recommends you have an A.S.E. Certified Technician install your parts to ensure your safety. ALWAYS WEAR SAFETY GLASSES AND OTHER SAFETY ITEMS WHEN PERFORMING THE FOLLOWING WORK The following information is simply a guideline and is not intended to replace the official factory manual. Always refer to the factory manual for proper installation and safety guidelines. 1) After following and completing the bumper cover removal guidelines, remove all decorative engine covers. 2) Drain all remaining coolant from the engine block by removing the oil cooler coolant hose located above the oil filter and also the furthest away from the front of the vehicle. 3) Remove the turbocharger coolant and vacuum hoses that run in front of the timing belt cover. Place these off to the side. (Image 1) 4) Use a 17mm wrench to rotate the ribbed belt tensioner in a clockwise direction to remove ribbed accessory belt. 5) Use an 8mm allen head socket wrench along with special tool # 3212 to remove the viscous fan. (Image 2) 6) With the fan removed, locate and remove the (3) fasteners holding the belt tensioner in place. 7) If applicable (AEB Engine Code models), remove the water pump v-belt and the (3) fasteners holding the 2 piece water pump pulley in place. (Image 3) Image 1 Image 2 Image 3 8) Remove the Air Conditioners ribbed belt by removing the (2) fasteners that hold the belt tensioner in place. 9) Remove the upper timing belt cover. 10) Rotate the engine to Top Dead Center (TDC). Check to assure that the engines timing marks line up. You will find alignment marks on the camshaft sprocket and valve cover, as well as marks on the lower crank pulley and lower timing belt cover. It is crucial that these marks are aligned properly. (Image 4 and 5) 11) Carefully remove the (4) fasteners on the lower ribbed belt pulley. Counter hold the crankshaft by using a 1/2 drive rachet and 19mm socket. Before fully removing the pulley, double check that the timing marks have not been disturbed. (Image 6) Image 4 Image 5 Image 6 Page 2 Copyright BLAUfergnügen! Inc Form # Ins145

Guidelines For Installation Of Your Audi 1.8T AEB, ATW Timing Belt Kit continued... 12) Remove the lower timing belt cover.

You should find (1) 10mm nut, (2) 10mm bolts, (1) 6mm allen and (1) 5mm allen. On models with ATW engine code, this is a two piece timing belt cover.

NOTE HOWEVER, on models with AEB engine code, BEFORE you remove the tension from the timing belt you will want to loosen the intermediate shaft pulley main bolt.

Hydraulic Damper, Tensioner Pulley and Tensioner Roller 15) Remove cam sprocket using cam sprocket counter holding tool # 3036 in order to install new seal.

3 Guidelines For Installation Of Your Audi 1.8T AEB, ATW Timing Belt Kit continued... 12) Remove the lower timing belt cover. On models with AEB engine code, This is a one piece timing belt cover and some of the fasteners are hidden and can be hard to see. You should find (1) 10mm nut, (2) 10mm bolts, (1) 6mm allen and (1) 5mm allen. On models with ATW engine code, this is a two piece timing belt cover. There is a total of 5 fasteners holding it in place. The fasteners are easier to see and access on this engine. (Image 7) 13) Remove tension from the timing belt by compressing the hydraulic damper. NOTE HOWEVER, on models with AEB engine code, BEFORE you remove the tension from the timing belt you will want to loosen the intermediate shaft pulley main bolt. This bolt, as well as one holding the front motor mount snub will need to be removed in order to install the water pump. 14) Remove all old timing belt related components, I.E. Hydraulic Damper, Tensioner Pulley and Tensioner Roller 15) Remove cam sprocket using cam sprocket counter holding tool # 3036 in order to install new seal. Remove the cam seal by using cam seal tool # Inspect the camshaft for a possible groove from the old seal wearing on camshaft. Lubricate the sealing lip of the new seal with fresh motor oil, then use tool # 3241/1 to gently tap new cam seal into place. If a groove existed, recess the new seal a few additional millimeters so that it rides on new surface area. Reinstall the cam sprocket and torque to 48 ft lbs. 16) Use special tool # 3099 along with a 19mm 12 point socket on a long breaker bar to remove lower crank toothed pulley s main bolt. Remove toothed pulley. Use care to not rotate crankshaft away from timing marks. (Image 8) 17) Use special tool # 3203 to remove lower crank seal. Inspect crankshaft for possible groove from old seal wearing on crankshaft seal surface area. Lubricate lip of new crank seal with clean motor oil, then use special tool #3265 to tap new crank seal into place. If a groove existed, recess the new seal a few additional millimeters so that it rides on new crankshaft surface area. (Image 9) 18) Reinstall lower crank toothed belt pulley and torque main fastener to 68 ft lbs + ¼ turn. Remove special tool # 3099 when done. Image 7 Image 8 Image 9 19) On models with AEB engine code, emove the tensioner pulley mounting stud as this will not be used with your new updated tensioner. (Image 10) 20) Remove the old water pump and install the new water pump. Be sure the mounting surface where the new water pump mates to is absolutely clean of the old gasket. 21) Remove the old thermostat. On models with AEB engine code, the coolant manifold and thermostat are located just below the lower backside of the water pump. On models with ATW engine code, the coolant manifold and thermostat are located just under the front side of the intake manifold. Release coolant hose clip and remove coolant hose. Next, remove the (2) fasteners holding the thermostat manifold in place. Be prepared to use a catch pan for a small amount of fluid left within this manifold even after draining the coolant system. Remove the old thermostat noting its orientation. Some thermostats may be difficult to remove because of the bond that can establish between dissimilar materials over time. A tap with the handle end of a small hammer handle may be in order. With thermostat removed, thoroughly clean out the recessed area where the new thermostat mates to the block. Install the new thermostat Image 10 with the same orientation as the old thermostat. 22) Reinstall the coolant manifold and torque to 7 ft lbs. 23) On models with AEB engine code, if the intermediate shaft sprocket was removed, reinstall now. - Torque spec: 48 ft lbs 24) If the front engine snub mount was removed reinstall now. 25) Install the new hydraulic tensioner damper and torque to 7 ft lbs. 26) Remove the tensioner roller fastener from the old hydraulic damper and use this fastener to install the new tensioner roller to the new hydraulic tensioner damper. - Torque spec: 15 ft lbs. Page 3 Copyright BLAUfergnügen! Inc Form # Ins145

Guidelines For Installation Of Your Audi 1.8T AEB, ATW Timing Belt Kit continued... 27) Install the new tensioner pulley and torque to 18 ft lbs. 28) Install the new timing belt.

On models with AEB engine code, you may see that the timing marks will appear as if your timing is off by one tooth.

4 Guidelines For Installation Of Your Audi 1.8T AEB, ATW Timing Belt Kit continued... 27) Install the new tensioner pulley and torque to 18 ft lbs. 28) Install the new timing belt. When installing the new timing belt, start by going around the lower crank and work your way up to the camshaft sprocket. On models with AEB engine code, you may see that the timing marks will appear as if your timing is off by one tooth. This is normal, but it is important that you set your belt in place such that the timing is set slightly retarded. Visually, the camshaft pulley marks should appear slightly rotated towards the drivers side. This will allow for any belt stretch. 29) After the new belt has been installed, you will want to re-check the timing marks on the camshaft and the crankshaft If these are not aligned you will need to realign as necessary. 30) With all the timing marks properly lined up, you can proceed to tension the timing belt. To do this, remove the pin from the new hydraulic tensioner damper and rotate the engine with a socket on the front crank 2 full revolutions in a clockwise direction. This allows the hydraulic tensioner damper to set proper tension on the belt. After rotation, recheck your timing marks. While rotating, at no time should any abrupt resistance be felt from interference by internal engine components. 31) Reinstall the lower timing belt cover and torque to 7 ft lbs. You may choose to apply a locking thread compound to these bolts. 32) Reinstall the lower serpentine belt crank pulley. Torque Spec 7 ft lbs + 1/4 turn. (Image 6) 33) Reinstall viscous fan and torque to 30 ft lbs. 34) Reinstall water pump pulley and all ribbed belt tensioners. You may consider installing the water pump V-belt along with the pulley to ease installation. Torque specs: Water pump pulley fasteners - 18 ft lbs. A/C belt tensioner - 15 ft lbs. Ribbed belt tensioner - 18 ft lbs. 35) Install all accessory belts. 36) Locate any components removed not specifically addressed in this guideline and re-install. 37) Review each step found in this set of guidelines to ensure each component has been addressed properly and has been re-fastened to specifications. Cooling System Filling: 38) Loosen the clamp on the coolant hose that runs up to the heater core. Pull the hose back until the small bleeder hole located near the end of the hose is no longer sealed as can be seen in Image ) Slowly fill the coolant expansion tank with a 50/50 mixture of coolant and water until it flows from the bleeder hole in the above heater core hose. 40) Push the heater hose back into place and re-affix clamp. 41) Top off coolant level to the maximum level mark of the expansion tank and install the expansion tank cap. 42) Start the engine and increase engine speed to around 2-3K for 3-5 min. 43) Allow engine to idle until the lower coolant hose on the radiator is hot. 44) Turn off engine. 45 When engine has cooled re-check coolant level and add as needed. 46) Check for coolant leaks. AEB Engine Code This parts bulletin applies to all hydraulic tensioner dampers Image 13 IMPORTANT!!!! If your timing belt tension was not properly applied or if you need to release your timing belt tension you will need to reset or compress the hydraulic tensioner damper. To avoid premature damage or failure of your hydraulic tensioner damper and tensioner pulley please continue as follows. 1) Avoid a OVERABUNDANT amount of pressure when compressing the hydraulic tensioner damper. 2) Compress the hydraulic tensioner damper in a slow manner taking in upwards of 2-5 minutes to do so. 3) Always compress the hydraulic tensioner damper on the vehicle as outlined by your factory bentley manual 3) Install locking pin or locking plate when in compressed position. 4) Set timing belt tension and timing of engine as outlined in your corresponding instruction form. (Failure to comply with these steps will damage your hydraulic tensioner damper and or pulley.) (Failure to heed this bulletin can cause the timing belt to skip a tooth and catastrophic engine damage) Page 4 Copyright BLAUfergnügen! Inc Form # Ins145

Guidelines For Bumper Cover Removal - Passat Applies to engine service when required! CAUTION!

Equipment, CAN CAUSE SEVERE INJURY OR DEATH! BLAUfergnugen! Inc. recommends you have an A.S.E. Certified Technician install your parts to ensure your safety.

guideline and is not intended to replace the official factory manual.

Front Bumper Cover Removal Guidelines - Passat 1) Remove (2) phillips screws on radiator support to remove air box intake

3) Use a 10 mm socket to remove (3) 8 mm bolts that secure hood latch to radiator support.

(Image 3) Image 1 Image 2 Image 3 5) Use a T-25 torx driver to remove the (3) screws on top of radiator support surrounding

5 Guidelines For Bumper Cover Removal - Passat Applies to engine service when required! CAUTION! Performing Work on Your Automobile Without Having Proper Knowledge, Mechanical Ability or the Proper Tools and Safety Equipment, CAN CAUSE SEVERE INJURY OR DEATH! BLAUfergnugen! Inc. recommends you have an A.S.E. Certified Technician install your parts to ensure your safety. ALWAYS WEAR SAFETY GLASSES AND OTHER SAFETY ITEMS WHEN PERFORMING THE FOLLOWING WORK The following information is simply a guideline and is not intended to replace the official factory manual. Always refer to the factory manual for proper installation and safety guidelines. Front Bumper Cover Removal Guidelines - Passat 1) Remove (2) phillips screws on radiator support to remove air box intake tube. (Image 1) 2) Remove hood seal gasket that runs across front radiator support from fender to fender. 3) Use a 10 mm socket to remove (3) 8 mm bolts that secure hood latch to radiator support. (Image 2) 4) Remove hood latch grommet. (Image 3) Image 1 Image 2 Image 3 5) Use a T-25 torx driver to remove the (3) screws on top of radiator support surrounding the hood latch. (Image 4) 6) Remove the drivers and passengers side turn signal lamps by removing spring clips. (Image 5) 7) Use a 10 mm socket to remove (1) front bumper cover bolt found in bottom edge of turn signal cavities on both drivers and passengers side of vehicle. (Image 6) Image 4 Image 5 Image 6 Page 5 Copyright BLAUfergnügen! Inc Form # Ins142

drivers and passengers side wheel wells in front of tires.

(Image 8) 10) Remove (2) Philips screws securing hood bump stops just to the inside of each headlamp.

forward until corner of cover comes loose.

If the hood latch release knob will not allow the hole in the bumper cover to clear, you may need to trim

When bumper cover has cleared the latch knob, grab the bumper cover and remove it, locating it in a safe

6 Installation of 2.8L 30 Valve V6 Timing Belt Kit continued: 8) Use a T-25 torx driver to remove (3) screws from each of both drivers and passengers side wheel wells in front of tires. (Image 7) 9) Use a T-25 torx driver to remove (1) 10 mm screw located behind inner fender skirt on both drivers and passengers side of vehicle. You must pry away the skirt material in order to obtain access to these screws. (Image 8) 10) Remove (2) Philips screws securing hood bump stops just to the inside of each headlamp. (Image 9) Image 7 Image 8 Image 9 11) Firmly grab passenger side corner of bumper cover gently pull forward until corner of cover comes loose. Gently manipulate the top center of the bumper cover over and clear of the hood latch release knob. If the hood latch release knob will not allow the hole in the bumper cover to clear, you may need to trim or enlarge the hole around the latch. When bumper cover has cleared the latch knob, grab the bumper cover and remove it, locating it in a safe place until it can be reinstalled. ( Images 10, 11 and 12) 12) Use a 13 mm socket to remove (2) front bumper reinforcement bolts and remove front bumper reinforcement ( Image 13) Image 10 Image 11 Image 12 Image 13 13) With bumper cover removed, you may now continue with related service. For reinstallation, step thru these guidelines in reverse order. When done, recheck all listed steps in order to ensure the work was done properly. Page 6 Copyright BLAUfergnügen! Inc Form # Ins142

Guidelines For Audi A4 1996-01 Front Bumper Removal! CAUTION!

Always refer to the factory manual for proper installation and safety guidelines. 1) Elevate vehicle on an automotive lift or proper jack stands and remove the lower splash pan.

If your vehicle does not have fog lights, just remove the lower bumper grilles.

This hose is located on the drivers side of the vehicle just behind the bumper cover.

7 Guidelines For Audi A Front Bumper Removal! CAUTION! Performing Work on Your Automobile Without Having Proper Knowledge, Mechanical Ability or the Proper Tools and Safety Equipment, CAN CAUSE SEVERE INJURY OR DEATH! BLAUfergnugen! Inc. recommends you have an A.S.E. Certified Technician install your parts to ensure your safety. ALWAYS WEAR SAFETY GLASSES AND OTHER SAFETY ITEMS WHEN PERFORMING THE FOLLOWING WORK The following information is simply a guideline and is not intended to replace the official factory manual. Always refer to the factory manual for proper installation and safety guidelines. 1) Elevate vehicle on an automotive lift or proper jack stands and remove the lower splash pan. 2) If your car is equipped with fog lights, you must unplug the lower fog lights. Remove the lower bumper grilles to access the the electrical plugs through the openings. If your vehicle does not have fog lights, just remove the lower bumper grilles. 3) Pinch off the vehicle side of the headlamp washer hose and push down on the plastic latch clip to separate the connector. This hose is located on the drivers side of the vehicle just behind the bumper cover. (Be careful not to break or destroy the clip as it will need to be reused) (Image 1) 4) Locate and remove the (2) fasteners from inner fender liner in front of each tire (one fastener on each side of vehicle). (Image 2) 5) Locate and remove (2) fasteners located in the top of each bumper grille opening (one fastener on each side of vehicle). (Image 3) Image 1 Image 2 Image 3 6) To slide the bumper cover out and off push strait down on the bumper cover between the fender and bumper cover seam just behind the headlight. At the same time well pushing down place your second hand near the wheel well area and pull out. The top of the bumper cover should pop out of the bracket. Then grab the lower side of the bumper and pull upward and out to pop the bumper cover out of the lower side of the bracket. Apply this step on both sides of the bumper cover. (Image 4) 7) Locate and remove the (2) fasteners that hold the air box intake to the radiator valance. Pull upward on the duct closest to the air box and then remove the duct. (Image 5) Image 4 Image 5 Page 7 Copyright BLAUfergnügen! Inc Form # Ins141a

Guidelines For Audi A4 1996-01 Front Bumper Removal continued.

9) Remove the upper and outermost fasteners located near the bumper shock brackets and then thread tool # 3369 into those same threaded holes.

(Image 6) 10) Locate and remove the (4) upper radiator valance fasteners located at the forward fender edge on each side of vehicle.

These fasteners are located just under headlamp on each side of the vehicle.

This cooler is located directly in front of the radiator/ac condensor. Let cooler tube hang free, but take care that it does not get damaged.

Drain the coolant from the system into a suitable drain pan.

8 Guidelines For Audi A Front Bumper Removal continued... 8) Remove the engine bay seal that runs across vehicle from fender to fender along the front side of the engine bay. 9) Remove the upper and outermost fasteners located near the bumper shock brackets and then thread tool # 3369 into those same threaded holes. When tool #3369 is in place on each side of the vehicle, remove the remaining fasteners from brackets. (Image 6) 10) Locate and remove the (4) upper radiator valance fasteners located at the forward fender edge on each side of vehicle. (Image 7) 11) Locate and remove the (2) fasteners holding the lower front edge of fender to the radiator valance. These fasteners are located just under headlamp on each side of the vehicle. (Image 8) Image 6 Image 7 Image 8 12) Locate and remove the (2) fasteners that hold the power steering cooler tube in place. This cooler is located directly in front of the radiator/ac condensor. Let cooler tube hang free, but take care that it does not get damaged. (Image 9) 13) Locate the radiator drain screw at the lower front drivers side of the radiator. Drain the coolant from the system into a suitable drain pan. (Image 10) 14) Remove both the upper and lower radiator hoses by gently prying with a screwdriver on the removal clip found integrated into the hose clamp. (Image 11) 15) If the vehicle has a 1.8L turbocharged 4 cylinder engine, you will need to remove the lower intercooler hoses that connect to the crossover pipe. 16) Slide the entire front radiator and support assembly forward along the previously installed special tools # Image 9 Image 10 Image 11 Page 8 Copyright BLAUfergnügen! Inc Form # Ins141a

PLEASE READ THE FOLLOWING BULLETIN BEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT

PLEASE READ THE FOLLOWING BULLETIN BEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT Bulletin: Prevent Premature Water Pump Failure! BLAUfergnugen! Inc. recommends that an Audi Vw Factory Trained ASE