Open Road

Got my car apart for another belt service after 12 years with a PKT. Belt looks brand new still, almost making me feel like I wasted my time.

I bought a new Audi tensioner but am retaining the belt roller since it's not noisy and has no unusual play.

Most of the pics of my progress are on IG under my tag: redrommel928

Anything I should know about refitting a replacement tensioner and a new belt?

Also debating about replacing the front of engine harness, the 14 pin connector one since the sheething on the ground is breaking off here and there.

Belts are like tires, they age out.

All the 12-year old bits that are rubber, are/contain a sealed bearing or are hydraulic need to go.

They will not likely last another 10-12 years.

For the PKT: make damn sure that "The Measurement" is within Ken's spec. If it isn't then, stop, do not pass go, contact Ken for instructions immediately.

Check your cam gears for wear. Might be time for front seals. Probably need to replace the PS pump supply hose and the hose section from the cooler loop to the reservoir.

The front main harness is easiest to replace while you are doing the belt. Watch out for the p-clamp that retains it to the engine carrier. That p-clamp is a bitch to get off and it only goes back on if the steering rack is loose from the carrier.

I was surprised how good the cam gears look. Almost no wear since 2013 when I last cracked it open based on comparison of prior photos.

No cam and crank seal leaks. Water pump is good. Only 963 miles passed in 12 years.

Thanks for the tip on that clamp! I am going to shop for an engine harness.

Mongo wrote: ↑Sat May 03, 2025 12:44 am Thanks for the tip on that clamp! I am going to shop for an engine harness.

Sean for the front harness.

Yeah that harness is a work of art. I will be back under the hood this weekend. Going to inspect the harness again before taking the plunge.

A lot got done yesterday. Installed the belt at 45 degree marks. The passenger cam gave me a little attitude but lined up in the end. Gave the engine 2 full rotations by hand back to TDC and the timing marks looked good. There were no areas where the belt had slack.

My only concern was when I took a hex key to measure piston extension, it looked like 8mm. Ken's PKT-S manual said it should be between 2-7mm with a new belt on a cold engine.

Closed everything up. Hope I don't have to go back in for another long period.

worf wrote: ↑Fri May 02, 2025 10:32 pm For the PKT: make damn sure that "The Measurement" is within Ken's spec. If it isn't then, stop, do not pass go, contact Ken for instructions immediately.

Mongo wrote: ↑Sun May 25, 2025 10:15 am My only concern was when I took a hex key to measure piston extension, it looked like 8mm. Ken's PKT-S manual said it should be between 2-7mm with a new belt on a cold engine.

And what did Ken say about it?

I can't make a horse drink.

I can only lead you to the water.

Good luck.

MY 1985 Engine Removed. Checking for valve and/or other damage.

Didn't ask him. I checked my record back in 2013 on extension and it was measured at 7mm with a caliper. I guess this means it's always been on the high side. This car has never had the heads off so no material has been removed that would cause that number to be out the window.

Found the instructions on the older version I have and it says it should not exceed 9mm. I guess I'm good and can sleep better.

Mongo wrote: ↑Tue May 27, 2025 3:49 pm Found the instructions on the older version I have and it says it should not exceed 9mm. I guess I'm good and can sleep better.

Ok. That's better.

Yep. I can sleep better tonight

I can say I took my sweet time on it. Everything is back together now but I need to reroute the fan wiring harness down the center still.

After that new coolant and oil, and its back around town cruising.

Mongo wrote: ↑Mon Jul 21, 2025 2:11 pm ... I need to reroute the fan wiring harness down the center still.

Did you forget to do that before you put the fan shroud in?

Yeah but its not a big deal to fix it the right way.

Well its running again and now I've got to help fix a funky hood latch on a non-Porsche.

Next projects for my car are new shocks and aluminum pedals.