Audi Workshop Service and Repair Manuals

Note:

Mark the running direction with chalk or felt pen before removing the toothed belt. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

• 120 Nm + 1/4 turn (90°) further
• ◆ Replace
• ◆ Do not oil
• ◆ To loosen and tighten use counterhold 3415
  => Fig.13-18
• 40 Nm + 1/4 turn (90°) further
• ◆ Replace
• 15 Nm

• 22 Nm
• ◆ Only vehicles as of 10.97
• Toothed belt guard - lower
• 10 Nm
• Toothed belt guard - centre
• 45 Nm
• ◆ Observe tightening sequence =>Fig.13-18
• Engine support
• ◆ Install => Fig.13-18
• Toothed belt guard - top
• ◆ For removal remove right air duct pipe
• ◆ When installing, engage carefully in centre toothed belt guard.

• Toothed belts
• ◆ Mark running direction with chalk or felt pen before removing
• ◆ Check for wear
• ◆ Removing
• ◆ Install (adjust valve timing) => Page 13-31.
• Idler roller
• ◆ Only vehicles as of 10.97
• Bolt
• ◆ Different versions
• ◆ Tightening torque => Fig.13-21
• 20 Nm
• 20 Nm

• 45 Nm
• ◆ Hold using counterhold 3036 for loosening and tightening camshaft sprocket
• Camshaft sprocket
• ◆ Pull off using special tool T40001 => Fig.13-19
• Semi-automatic toothed belt tensioning roller
• ◆ Checking => Page 13-40
• ◆ Installation position => Fig.13-19
• Idler roller
• Injection pump sprocket
• ◆ Two-piece
• ◆ Different versions. Allocation of bolts -Item 13-21
• ◆ Removing and installing => Fig.13-20

• 30 Nm
• Toothed belt guard - rear
• ◆ Engage in front at lower edge behind sealing flange.
• Coolant pump
• ◆ Removing and installing
• Idler roller
• ◆ Unscrew to remove coolant pump
• Crankshaft sprocket
• ◆ Contact surface between sprocket and crankshaft must be free of oil
• ◆ Can only be installed in one position

• Threaded bushing
• Injection pump
• ◆ Never loosen central nut
• ◆ Removing and installing

=> Diesel Direct Injection and Glow Plug System (4-cyl. TDI) > 07.99; Repair group 23

=> TDI Injection and Glow Plug System (4-cyl.) 08.99 >; Repair group 23

• Bracket for auxiliary mechanical units
• 45 Nm

→ Fig.1    Removing and installing crankshaft sprocket

• ‒ Use counter-hold tool 3415 to loosen and tighten the central bolt.

→ Fig.2    Installing engine support

• ‒ Insert bolts -1 ... 3- hand-tight initially.
• ‒ Then tighten the bolts -1 ... 3- to 45 Nm.

→ Fig.3    Pull camshaft sprocket off camshaft

• ● Toothed belt removed => Page 13-23

• ‒ Unscrew the camshaft sprocket bolt one half turn .
• ‒ Place the two-arm puller T40001 with claw T40001/2 -Item A- and the two-arm claw T40001/3 -Item B- centralised onto the camshaft sprocket.
• ‒ Pull off the camshaft sprocket using the two-arm puller. Counterhold using an open-end spanner -C- in the process.

→ Fig.4    Fitting location of semi-automatic tensioning roller

Retaining lug -arrow- must engage in rear toothed belt guard slot.

→ Fig.5    Removing and installing injection pump sprocket

• ‒ When installing the injection pump sprocket, note the different securing bolts -1- => Fig.13-21.

→ Fig.6    Different securing bolts for injection pump sprocket

A - Version with tip and punch mark -arrows-:

• ‒ Use only for injection pump sprocket with part-No. 038 130 111 A
• ‒ Tightening torque: 20 Nm + 90° (1/4 turn)
• ‒ Replace bolt after each loosening operation

B - Version without tip and punch mark:

• ‒ Use only for injection pump sprocket with part-No. 038 130 111 B
• ‒ Tightening torque: 25 Nm
• ‒ Bolt may be re-used