Audi Workshop Service and Repair Manuals

Removing and installing toothed belt   Note

t  The engine support has to be removed and the engine supported from above in order to remove the toothed belt on vehicles with small engine support -version 1-. t  The engine support remains installed on vehicles with large engine support -version 2-.

Special tools and workshop equipment required

t	Locking pin -3359-

t	Engine bung set -VAS 6122-

t	Crankshaft stop -T10100-

t	Counter-hold tool -T10172- with pin -T10172/4-

t	Angle driver -T10264-

t	Locking tool -T10265-

t  Support bracket -10 - 222 A- for vehicles with small engine support t  Locking fluid → Electronic parts catalogue

Removing –  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

WARNING t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. –  Disconnect fuel supply hose -2- and fuel return hose -1- from fuel lines. –  Detach coolant hose -3-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove bolt -1-. –  Remove air pipe (right-side) by lifting retaining clips -arrows- slightly.

–  Pull release tabs and disconnect fuel supply pipe -3- and fuel return pipe -2-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-. –  Detach coolant hose -1- at expansion tank. Vehicles with auxiliary heater: –  Disconnect fuel pipe (press release tab). –  Move fuel pipe clear.

All vehicles (continued): –  Pull fuel filter with hoses attached upwards out of the bracket -arrow- and place to side.

–  Unscrew bracket -3- for fuel filter. –  Unscrew bolt at filler neck -2- for washer fluid reservoir. –  Detach electrical connector at coolant expansion tank -1-. –  Unbolt coolant expansion tank and lay it aside with hoses connected. –  Remove poly V-belt: vehicles with tensioner → Chapter, vehicles without tensioner → Chapter.

–  Vehicles with tensioner: remove bolts -arrows- and take off tensioner for poly-V-belt.

–  Remove top toothed belt cover by releasing retaining clips -arrows-.

Vehicles with small engine support –  Set up support bracket -10-222 A- with adapters -10-222 A/3- on wing panel flanges. –  Attach hooks of spindles to lifting eyes. –  Take up weight of engine evenly with both spindles (but do not raise engine).

–  Remove bolts -1- and -2- and detach connecting bracket. –  Remove bolts -3 ... 6- and remove engine mounting.

All vehicles (continued): –  Remove front right wheel. –  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-.

–  Remove cover cap for vibration damper. –  Unbolt vibration damper; counterhold on centre bolt with ring spanner.

–  Unbolt toothed belt cover (centre and bottom) -arrows-.

Vehicles with small engine support –  Remove bolts -1 ... 3- for engine support.   Note To remove the bolts for the engine support, raise or lower the engine slightly as necessary via the spindles on support bracket -10-222 A-. –  Raise engine/gearbox assembly slightly via the two spindles and remove engine support.

All vehicles (continued):   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).   Note Turn over the engine at the central bolt on the crankshaft. –  Turn the crankshaft to TDC. l  The toothed segment -arrow- at camshaft sprocket must face upwards. l  The lug -1- on sender wheel for camshaft must align with the marking -2- on rear toothed belt cover (not fitted on all versions).   Note The camshaft sprocket is shown with the toothed belt removed for illustrative purposes. –  Lock hub with locking pin -3359-.

–  Lock crankshaft sprocket with crankshaft stop -T10100-. l  The markings on the sprocket -2- and the crankshaft stop -1- must align. The lug of the crankshaft stop must engage in the bore in the sealing flange.   Note The crankshaft stop can only be pushed onto the sprocket from the front face of the teeth.

–  Mark direction of rotation of toothed belt with chalk or felt pen. –  Loosen securing bolts for camshaft sprocket -arrows-.

–  Loosen securing nut -1- for tensioning roller. –  Turn the eccentric adjuster with the angle driver -T10264- anti-clockwise -arrow- until the tensioning roller can be secured with the locking tool -T10265-.

–  Now turn eccentric adjuster of tensioning roller clockwise -arrow- until stop and tighten securing nut -1- finger-tight. –  Take off toothed belt first from coolant pump and then from the remaining sprockets. Installing (adjusting valve timing) l  Camshaft locked with locking pin -3359-. l  Crankshaft locked with crankshaft stop -T10100-. l  Tensioning roller locked with locking tool -T10265- and secured at right stop with securing nut.   Note t  Toothed belt adjustment must always be performed when the engine is cold. t  The crankshaft must not be at TDC at any cylinder when the camshaft is turned. Otherwise, there is a risk of damage to valves and piston crowns.

–  Ensure that tensioning roller is seated properly in rear toothed belt cover -arrow-.

–  Screw in bolts -arrows-, but do not tighten. l  It should just be possible to turn the camshaft sprocket on the hub without axial movement. –  Turn the camshaft sprocket in its elongated hole clockwise until the stop. –  Guide toothed belt in from above between engine support and engine. –  Fit toothed belt first onto camshaft sprocket, tensioning roller, crankshaft sprocket and then onto coolant pump sprocket.

–  Adjust toothed belt tension as follows: –  Remove locking tool -T10265- from tensioning roller. –  Loosen securing nut -1- for tensioning roller. –  Turn eccentric adjuster of tensioning roller clockwise -arrow- using angle driver -T10264- until pointer -2- aligns with the centre of the slot on the base plate.   Note t  Make sure that the securing nut does not also turn. t  Shown in illustration without engine support. –  Hold tensioning roller in this position and tighten tensioning roller nut to 20 Nm + 45 .   Note When tightening the securing nut, the pointer may move up to 5 mm (maximum) to the right of the slot in the base plate. This position must not be corrected, because the toothed belt stretches slightly when running in.

–  Insert counterhold tool -T10172- with pins -T10172/4- as shown in illustration and pretension driving section of toothed belt by pressing in direction of -arrow-. –  Tighten bolts -1- on camshaft sprocket to 25 Nm. –  Remove locking pin -3359- and crankshaft stop -T10100-. Checking valve timing:   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise). –  Turn crankshaft two rotations in normal direction of rotation until the crankshaft is just before TDC again.

–  Lock the camshaft hub into place with the locking pin -3359- while turning. –  Check whether: l  The crankshaft can be locked with the crankshaft stop -T10100-. l  The tensioner pointer is centred or a maximum of 5 mm to the right of the slot in the base plate. If the crankshaft cannot be locked: –  Loosen securing bolts for camshaft sprocket -arrows-.

–  Turn the crankshaft slightly further in the normal direction of rotation until it can be locked with crankshaft stop -T10100-.   Note If the crankshaft has been rotated beyond TDC, turn it back slightly so you can then reset it to TDC by turning in the normal direction of rotation.

–  Tighten securing bolts for camshaft sprocket -arrows- to 25 Nm. –  Remove locking pin -3359- and crankshaft stop -T10100-.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise). –  Turn crankshaft two rotations in normal direction of rotation until crankshaft is at TDC again. –  Check valve timing once again → Anchor. Assembling: Remaining installation steps are carried out in reverse sequence; note the following: –  Install centre and bottom sections of toothed belt cover.   Note t  Renew seals and gaskets. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Secure engine support → Chapter. –  Install vibration damper → Chapter. –  Adjust assembly mountings → Chapter. –  Install poly V-belt: vehicles with tensioner → Chapter, vehicles without tensioner → Chapter. Tightening torques

Component	Nm
Tensioning roller for toothed belt to cylinder head	20 + 45°
Camshaft sprocket to hub	25
Toothed belt cover (bottom) to cylinder block	10 1)
Toothed belt cover (centre) to cylinder block	10 1)
Tensioner for poly V-belt to bracket for ancillaries	23
Air pipe (right-side) to bracket	8
l  1) Apply locking fluid when installing; refer to → Electronic parts catalogue for locking fluid.