Audi Workshop Service and Repair Manuals

Removing and installing toothed belt - vehicles up to approx. 05.2005   Note

On vehicles up to approx. 05.2005 (can be identified by engine support -version 1-), the engine support has to be removed before removing the toothed belt.

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Diesel injection pump locking pin -3359-

t	Hose clip pliers -VAS 6340- or -VAS 5024 A-

t	Pin wrench -T10020-

t	Crankshaft stop -T10050- for engines with circular crankshaft sprocket

t	Locking pin -T10060 A- or -T10060-

t	Crankshaft stop -T10100- for engines with oval crankshaft sprocket

t	Locking pin -T10115-

t	Counterhold tool -T10172-

t	Locking fluid → Parts catalogue

Removing –  Lift engine cover panel at sides -arrows 1- and pull off towards front -arrow 2-.

–  Detach the hoses/lines -1 ... 3- from air pipe. –  Remove air pipe by lifting retaining clips -arrows- slightly.   Note Leave coolant hose -1- and fuel lines -2- and -3- connected.

–  Detach electrical connector -arrow- at intake manifold flap motor -V157-. –  Unscrew bolts -1 ... 3- and detach intake manifold flap motor -V157-.

–  Disconnect vacuum hose -3- at exhaust gas recirculation valve -N18-. –  Detach pipe -4- for crankcase breather at air pipe. –  Release hose clip -1- at turbocharger using hose clip pliers -VAS 6340-. –  Move the vacuum hoses clear -arrow-. –  Unscrew bolts -2- and -5- and remove air pipe.   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 pipe -2- and fuel return pipe -1- by pulling release tabs.

–  Release catches and 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. –  Unscrew coolant expansion tank -1- and place on top of cylinder head cover with the hoses attached.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  To slacken the poly V-belt, turn the tensioner in the direction of the -arrow-.

–  Lock tensioner for poly V-belt in position with locking pin -T10060 A- or -T10060-. –  Remove poly V-belt.

–  Remove tensioner for poly V-belt -arrows-.

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

–  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 (do not raise).

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

–  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove bolts -1- and -2-. –  Remove air pipe (right-side) by lifting retaining clips -arrows- slightly.

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

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

–  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 with spindles and remove engine support.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Turn the crankshaft to TDC for cylinder No. 1. l  Toothed segment -arrow- in 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 Camshaft sprocket is shown in illustration with toothed belt removed. –  Lock hub on camshaft with locking pin -3359-.

–  Lock crankshaft sprocket using crankshaft stop -T10050- for engines with circular crankshaft sprocket, or crankshaft stop -T10100- for engines with oval crankshaft sprocket. l  The markings on the toothed belt sprocket and the crankshaft stop must align -arrow-. 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 eccentric adjuster anti-clockwise -arrow- using pin wrench -T10020- until tensioning roller can be secured with locking pin -T10115-.   Note Instead of using the pin wrench -T10020-, you can also use the 2-hole pin wrench -3387-.

–  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  Hub on camshaft is locked with locking pin -3359-. l  Crankshaft is locked using crankshaft stop -T10050- for engines with circular crankshaft sprocket, or crankshaft stop -T10100- for engines with oval crankshaft sprocket. l  Tensioning roller is locked with locking pin -T10115- 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. –  Fit toothed belt onto sprockets (coolant pump last).

–  Adjust toothed belt tension as follows: –  Remove locking pin -T10115-. –  Loosen securing nut -1- for tensioning roller. –  Turn eccentric adjuster of tensioning roller clockwise -arrow- using 2-hole pin wrench -T10020- until pointer -2- aligns with centre of slot in base plate.   Note Make sure that the securing nut -1- on the tensioning roller does not turn at the same time. –  Hold tensioning roller in this position and tighten securing nut -1- on tensioning roller to 20 Nm + 45° (1/8 turn).   Note When tightening the securing nut -1-, the pointer -2- 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.

–  Attach counterhold tool -T10172- with pins -T10172/4- as illustrated and apply tension to driving section of toothed belt by pressing in direction of -arrow-. –  Tighten bolts -1- on camshaft sprocket to 25 Nm. –  Remove locking pin and crankshaft stop. 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 using crankshaft stop -T10050- for engines with circular crankshaft sprocket, or crankshaft stop -T10100- for engines with oval crankshaft sprocket. 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 -T10050- or -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 and crankshaft stop.   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 TDC again. –  Check valve timing once again → Anchor. Assembling Perform further installation in reverse order, paying attention to the following: –  Install toothed belt cover (bottom and centre).   Note t  Renew bolts for engine support. t  Renew seals and gaskets. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Secure engine support → Chapter. –  Install vibration damper → Chapter. –  Adjust assembly mountings → Chapter. –  Install air pipes/hoses with plug-in connectors → Chapter. –  Install poly V-belt → Chapter. Tightening torques

Component		Nm
Tensioning roller for toothed belt to cylinder head		20 + 45° 1)
Camshaft sprocket to hub		25
Toothed belt cover (bottom) to cylinder block		10 2)
Toothed belt cover (centre) to cylinder block		10 2)
Engine mounting to body		50
Connecting bracket to engine mounting/body		20 + 90° 3)4)
Tensioner for poly V-belt to bracket for ancillaries		23
Air pipes to engine		8
l  1) 45° = one eighth turn. l  2) Install using locking fluid; refer to → Parts catalogue. l  3) Renew bolts. l  4) 90° = one quarter turn.