Audi Workshop Service and Repair Manuals

Removing and installing toothed belt

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Tensioning bolt -T10092-

t	Locking pin -T40011-

Removing –  Remove poly V-belt → Chapter. –  Remove poly V-belt tensioner -arrows-.

–  Detach coolant expansion tank -1-, power steering reservoir -2- and activated charcoal filter -3-. Hoses remain connected.

WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection. –  Disconnect fuel supply pipe -1- and fuel return pipe -2- by pressing release tabs.

–  Detach vacuum line -2- from intake manifold.   Note Disregard -item 1-.

–  Turn crankshaft to “TDC”: With engine installed → Chapter, with engine removed → Chapter. –  Unbolt vibration damper; counterhold on centre bolt with ring spanner.

–  Unbolt lower and centre toothed belt covers -arrows-.

–  Set up support bracket -10-222 A- on wing panel flanges. l  The spindle is located at the front. –  Attach hook on spindle to engine lifting eye (right-side). –  Lift engine slightly with spindle of support bracket -10-222 A-. –  Tie up coolant expansion tank and power assisted steering reservoir on engine support bracket.

–  Unbolt engine mounting and connecting bracket from body and from engine support -arrows-. –  Remove engine mounting.

–  Remove bolts for engine support -arrows- but do not take out the engine support.   Note To remove the bolts for the engine support, raise or lower the engine slightly as necessary via the spindle on support bracket -10-222 A-.

–  Screw tensioning bolt -T10092- into toothed belt tensioner. –  Compress piston of tensioner just far enough so that the piston can be locked with locking pin -T40011-.   Note Bend locking pin -T40011- approx. 90° so it can be inserted more easily. –  Mark direction of rotation of toothed belt with chalk or felt pen. –  Pull out toothed belt through space between engine support and cylinder block.

Installing (adjusting valve timing)   Caution When turning the camshaft, the crankshaft must not be at “TDC”. Otherwise, there is a risk of damage to valves and piston crowns. –  Check that marking on camshaft sprocket is aligned with marking on cylinder head cover -arrows-.

–  Check again that crankshaft is positioned at TDC -arrow-. –  Fit toothed belt onto crankshaft sprocket, noting direction of rotation. –  Fit toothed belt onto remaining sprockets in the sequence: coolant pump, tensioning roller, camshaft sprocket.

–  Remove tensioning bolt -T10092-. –  Remove locking pin -T40011- from tensioner. l  Piston of toothed belt tensioner is released. –  Turn crankshaft at central bolt on toothed belt sprocket two revolutions in direction of engine rotation and check whether camshaft and crankshaft markings align with their respective reference points. –  Install toothed belt cover. Installation is carried out in the reverse order; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Install vibration damper → Chapter.

–  Install engine support -arrows-. –  Adjust assembly mountings → Chapter. –  Install poly V-belt → Chapter. –  Install coolant expansion tank, power steering reservoir and activated charcoal filter. Tightening torques

Component	Nm
Toothed belt cover (bottom) to cylinder block	10 1)
Toothed belt cover (centre) to cylinder block	10 1)
Engine support to cylinder block	45
Connecting bracket to body/engine mounting	25
Engine mounting to body	40 + 90° 2)3)
Tensioner for poly V-belt to bracket for ancillaries	23
l  1) Install using locking fluid; for locking fluid refer to → Parts catalogue. l  2) Renew bolts. l  3) 90° = one quarter turn.