Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Pin wrench 3212
• ◆ Rig pin 3359
• ◆ Pin wrench 3387
• ◆ Locking plate T10008
• ◆ Crankshaft stop T10050
• ◆ Drill ø4 mm
• ◆ Locking fluid

=> Parts List

Removing

• ● Engine in position
• ● Lock carrier in service position =>Page 13-1.

• ‒ → Pull dipstick -1- out of guide tube.
• ‒ Unclipcaps.
• ‒ Remove nuts -arrows- and detach engine cover.
• ‒ Remove insulation lying below.
• ‒ Re-insert dipstick into guide tube.
• ‒ Remove ribbed belt => Page 13-23.

• ‒ → Counter hold pulley for viscous fan with 2-hole pin wrench 3212 and unscrew from bracket with 8 mm Allen key -1-.
• ‒ Detach viscous fan.

• ‒ → Screw out bolts -1- and -2- and detach ribbed belt tensioner.

• ‒ → Unbolt coolant pipe brackets -1- and -2-.

Note:

The coolant hoses can remain connected to the lines.

• ‒ Remove top toothed belt guard -arrows-.

• ‒ → Screw out bolts -3- and detach cover -2-.
• ‒ Place aside charge pressure control solenoid valve -1- with connected hoses.

• ‒ Lift trim cap off of vibration damper.
• ‒ → Unscrew vibration damper.

Note:

Provide support with box wrench at central bolt when unfastening and tightening vibration damper.

• ‒ → Unbolt centre and bottom toothed belt guards -arrows-.

Note:

Use central bolt of crankshaft as application point for cranking engine.

• ‒ → Rotate crankshaft to cylinder 1 TDC.

Notes:

• ◆ The gap between the two lugs -1- on the camshaft sender wheel must be positioned opposite the "4Z" marking -item 2- on the toothed belt guard.
• ◆ The illustration shows the camshaft sprocket without the toothed belt.

• ‒ Lock hub with rig pin 3359.

• ‒ → Lock crankshaft toothed belt sprocket with crankshaft stop T10050.

Notes:

• ◆ The markings on the toothed belt sprocket -2- and on the crankshaft stop -1- must face each other. The journal of the crankshaft stop must engage in the sealing flange hole.
• ◆ The crankshaft stop can only be pushed onto the toothed belt sprocket from the front face of the splines.

• ‒ → Insert an Allen key all the way into the hex socket and use it to push the tensioning roller anti-clockwise -direction of arrow- until you can lock the toothed belt tensioner with locking plate T10008.

Notes:

• ◆ Insert the Allen key all the way, to avoid damage.
• ◆ The toothed belt tensioning element is oil-damped, and can only be pushed back slowly, applying force smoothly and evenly.

• ‒ Mark direction of toothed belt with chalk or felt-tip pen.
• ‒ Slacken tensioning roller nut.
• ‒ → Remove toothed belt tensioner bolts -arrows- and detach tensioner.
• ‒ Detach toothed belt.

Installing (adjusting valve timing)

• ● Camshaft locked with rig pin 3359.
• ● Crankshaft locked with crankshaft stop T10050.
• ● Toothed belt tensioner locked with locking plate T10008.

Notes:

• ◆ Only carry out adjustments to the toothed belt when the engine is cold.
• ◆ When the camshaft is rotated, no crankshaft piston must be positioned at TDC, as this could result in valve/piston crown damage.

• ‒ → Slacken camshaft sprocket bolts -arrows-.

• ‒ → Screw bolts -arrows- in hand-tight.
• ‒ The camshaft sprocket must just about still turn, and must not tilt.
• ‒ Rotate the camshaft sprocket in its slots clockwise all the way to the limit.
• ‒ Position toothed belt on camshaft sprocket, tensioning roller, crankshaft toothed belt sprocket and, lastly, on water pump toothed belt.
• ‒ Install toothed belt tensioner.

• ‒ Adjust toothed belt tension as follows:
• ‒ → Turn eccentric disk fully anti-clockwise using nut driver 3387 -A-.
• ‒ Withdraw locking plate T10008.

• ‒ → Slowly lower your resistance to the clockwise counterforce of the tensioner until a drill ø 4.0 mm -item 2- can be drawn easily between the tensioning lever and the housing of the tensioner by the shaft.
• ‒ Dimension a = 4.0 ± 1.0 mm
• ‒ Hold tensioning roller firm in that position and tighten nut of tensioning roller -1- to 20 Nm + 45° (1/8 turn).

• ‒ → Tighten camshaft sprocket bolts -arrows- to 25 Nm.
• ‒ Remove rig pin 3359 and crankshaft stop T10050.

• ‒ Rotate the crankshaft two turns in the direction the engine is turning until it is again positioned at TDC.
• ‒ → Check again that dimension -a- is reached between tensioning lever and tensioner housing.
• ‒ Dimension a = 4.0 ± 1.0 mm
• ‒ If dimension -a- is not reached, retension tensioning roller as follows:
• ‒ Hold tensioning roller firm with nut driver 3387, slacken nut -1- and lower resistance to counterforce of tensioner -arrows- until dimension -a- is reached.
• ‒ Dimension a = 4.0 ± 1.0 mm
• ‒ Hold tensioning roller firm in that position and tighten nut of tensioning roller -1- to 20 Nm + 45° (1/8 turn).

Checking valve timing

• ‒ → Lock crankshaft toothed belt sprocket again as a check with crankshaft stop T10050.

Notes:

• ◆ The markings on the toothed belt sprocket -2- and on the crankshaft stop -1- must face each other.- The journal of the crankshaft stop must engage in the sealing flange hole.
• ◆ The journal of the crankshaft stop must engage in the hole in the sealing flange as it rotates.
• ◆ If the crankshaft has been rotated beyond cylinder 1 TDC, turn it a quarter turn back to reset it to cylinder 1 TDC in the direction of rotation of the engine. No corrections against the direction of rotation of the engine to reset the crankshaft stop must be made.

• ‒ → Check with rig pin 3359 that hub can be locked.

Notes:

• ◆ The gap between the two lugs -1- on the camshaft sender wheel must be positioned opposite the "4Z" marking -item 2- on the toothed belt guard.
• ◆ The illustration shows the camshaft sprocket without the toothed belt.

If hub cannot be locked:

• ‒ → Slacken camshaft sprocket bolts -arrows-.
• ‒ Position a box wrench at the camshaft centre bolt.
• ‒ Turn hub until rig pin 3359 can be pushed in.
• ‒ Tighten camshaft sprocket bolts -arrows- to 25 Nm.
• ‒ Remove rig pin 3359 and crankshaft stop T10050.

• ‒ Rotate the crankshaft two turns in the direction the engine is turning until it is again positioned at TDC.
• ‒ Repeat check of valve timing =>Page 13-47.

• ‒ → Bolt viscous fan onto mount -1-, bracing viscous fan pulley with pin wrench 3212 to do so.
• ‒ Install ribbed belt =>Page 13-24.
• ‒ Install lock carrier =>Page 13-1.

Tightening torques

    1)    45°corresponds to one eighth of a turn

    2)    Insert with locking fluid1;
        For locking fluid refer to

=> Parts List

    3)    Replace bolts

    4)    90°corresponds to quarter of a turn