Audi Workshop Service and Repair Manuals

(Adjusting valve timing)

Special tools, workshop equipment, test and measuring appliances and auxiliary items required

• ◆ 10-222A Support bracket
• ◆ V.A.G 1331 Torque wrench (5...50 Nm)
• ◆ V.A.G 1332 (40...200 Nm) Torque wrench
• ◆ Spanner

Removing

• ‒ Remove air cleaner:

=> Repair group 24; Servicing injection system; Removing and installing air cleaner

• ‒ Remove protective plate from exhaust manifold.
• ‒ Mark the direction of rotation of ribbed belt and remove , Removing and installing ribbed belt.

Vehicles with air conditioner

• ‒ Remove ribbed belt idler roller.

Continuation for all vehicles

• ‒ Remove tensioning element for ribbed belt.
• ‒ Remove coolant expansion tank (coolant hoses remain connected).
• ‒ Remove reservoir for power assisted steering (hoses remain connected).

• ‒ Remove toothed belt guard - upper part.

• ‒ → Remove crankshaft belt pulley.
• ‒ Remove lower toothed belt guard.

• ‒ → Fit support device 10-222 A as shown and support engine in its installation position.

• ‒ → Remove securing bolts from assembly mounting/engine mounting, assembly mounting/body and assembly mounting/body mounting -arrows- and remove assembly mounting complete.
• ‒ Remove engine mounting on cylinder block.
• ‒ Mark D.O.R. of toothed belt.
• ‒ Release tensioner and take off toothed belt.

Installing

Prerequisites

• ● The engine must be no more than warm to touch.
• ● The pistons must not be positioned at TDC.

Note:

If a piston is at TDC the valves could strike the piston when turning the camshaft.

Work sequence

• ‒ → Set camshaft sprocket to mark -arrow A-.
• ‒ Set crankshaft to TDC No. 1 cylinder. The ground tooth on the crankshaft toothed belt pulley must align with the marking -2V- on the sealing flange -arrow B-.
• ‒ Fit toothed belt. For used belts note direction of rotation.

• ‒ → Tighten tensioning roller securing bolt hand-tight. The slot in the base plate -1- must locate around securing bolt -2- .
• ‒ Tension toothed belt by turning the tensioning roller in direction of arrow until the indicator -3- aligns with the groove in the base plate -arrow-.

• ‒ Tighten clamping bolt on tensioning roller.
      Tightening torque: 20 Nm
• ‒ Now turn the crankshaft two turns in engine direction of rotation until it is again at top dead centre No. 1 cylinder.
• ‒ Now the position of the toothed belt and tensioning roller must be checked again.
• ‒ Fit right engine bracket to cylinder block.
      Tightening torque: 50 Nm.
• ‒ Install lower toothed belt guard.
• ‒ Install crankshaft belt pulley (note fixing arrangement).
      Tightening torque: 20 Nm
• ‒ Install tensioning element for ribbed belt.
  Tightening torque:
      M8: 20 Nm + 1/4 turn (90°)further
      M10: 45 Nm

Vehicles with air conditioner

• ‒ Install ribbed belt idler roller.
      Tightening torque: 45 Nm

Continuation for all vehicles

• ‒ Install protective plate for exhaust manifold.
      Tightening torque: 10 Nm
• ‒ Install engine assembly mounting.
  Tightening torque => Page 10-19.
• ‒ Install upper toothed belt guard.
• ‒ Install power assisted steering reservoir and coolant expansion tank.
• ‒ Install ribbed belt => Page 13-9.

Note:

When installing the ribbed belt ensure that it sits correctly in the pulleys.