Timing belt job and missing clip for crosspipe to intercooler

Eric_R_Kissell at whirlpool.com Eric_R_Kissell at whirlpool.com
Mon Nov 24 16:23:55 EST 2003

I dug into the eBay surprise 1991 200q 20v Avant this weekend to change the
timing belt and related parts.

The first thing I did was to make a crank locking tool out of 2x2 square
tubing, 6 inches long (could have been 4 inches) with 1.5 inches of one
side removed on one end.  I paid $1 for the short piece of square tubing,
cut the side out with a jig saw, and ground the four corners down slightly
with a hand grinder. This was utilized with a 14 inch long pipe wrench and
worked flawlessly.

As I disassembled the car to change the timing belt I discovered:
1. there was only 1 of the 2 clips that holds the cross-pipe to the
intercooler at the clamp
2. there was no o-ring on the cross-pipe to the intercooler  joint
3. I cannot find any mark on the flywheel associated with TDC

I had a spare single-pass intercooler assembly that I plan to put in my
5ktq, so I borrowed the missing crosspipe to intercooler clip from that.
Does anyone have an extra one of these clips so I have it when I put the
single-pass intercooler into my 5ktq? Please :-)

I had a new intercooler o-ring ready to go, so that is no problem.

Can anyone comment as to why I cannot see a mark on the flywheel? I slowly
turned the engine and looked at an entire rotation of the flywheel but I
could not find a mark anywhere.  I put it back together in the same spot
that I found it set, but I would really like to know that the flywheel is
in the right location.

Eric Kissell
1991 200q 20v Avant, Koni Sports (yellow), eBay Surprise
1989 200q 10v Avant, Boge Turbogas, 1.8 Bar (qlcc)
1986 5000cstq Sedan, Bilsteins, 1.8 Bar (SJM)

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