Audi Workshop Service and Repair Manuals

Removing

• ● Engine in vehicle
• ● Lock carrier must be in service position .

Special tools, testers and auxiliary items

• ◆ Pin wrench 2587

• ‒ Remove ribbed belt and tensioning element for ribbed belt => Page 13-17.
• ‒ Remove viscous fan coupling (with belt pulley) => Fig. 13-16.
• ‒ Remove toothed belt guard (top).

• ‒ Mark direction of rotation of belt with chalk or felt pen.
• ‒ → Set crankshaft to mark for TDC of No. 1 cylinder -arrows- by turning central bolt on crankshaft sprocket in direction of rotation ....

• ‒ → ... and at the same time check that mark on camshaft sprocket is aligned with mark on toothed belt guard. If necessary, turn crankshaft 1 turn further.

• ‒ → Remove crankshaft pulley.

• ‒ → Unbolt toothed belt guard (bottom section) -arrows-.

• ‒ → Loosen toothed belt tensioner with Torx wrench T45 -lower arrow-.
• ‒ Press toothed belt tensioner downwards.
• ‒ Take toothed belt off camshaft sprocket.

Installing (adjusting valve timing)

Notes:

• ◆ The position of the toothed belt must be set as described below, even after repairs in which the belt is only taken off the camshaft sprocket.
• ◆ 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.
• ◆ The setting can be performed with engine cold or engine warm.

• ‒ → Bring mark on camshaft sprocket into line with mark on toothed belt guard -arrows-.

• ‒ → Bring mark (dot) on intermediate shaft sprocket -1- into line with mark on crankshaft pulley -2-.

Note:

The "OT" mark -3- on the intermediate shaft sprocket has no significance and can be disregarded.

• → If intermediate shaft sprocket is set correctly, distributor rotor should be in line with mark for cylinder No. 1 on distributor housing.

• ‒ If necessary, check setting of intermediate shaft sprocket.
• ‒ If this setting is OK, loosen distributor mounting and adjust distributor, or remove and re-install distributor:

=> Motronic injection and ignition system (4-cylinder); Repair Group 28; Checking distributor ignition system (ADP engine); Installing distributor

• ‒ Place toothed belt on crankshaft sprocket (observe direction of rotation).
• ‒ Install toothed belt guard - lower part.

• ‒ Secure crankshaft pulley with one bolt (note fixing arrangement).
• ‒ → Check again that TDC mark on crankshaft pulley is in line with reference mark -arrows-. The toothed belt guard (lower part) and crankshaft pulley are installed temporarily in order to make this check.
• ‒ Place toothed belt on tensioning roller and camshaft sprocket.

• ‒ → Tension toothed belt: to do this turn tensioner -A- using pin wrench -B- (e.g. Hazet 2587) clockwise until piston -1- is fully extended and tensioner piston -2- lifts approx. 1 mm.
• ‒ Tighten securing bolt -3- hand-tight.
• ‒ Turn crankshaft two full turns and check whether camshaft and crankshaft marks align with their reference points.

• ‒ → Check that area -A- coincides with upper end of piston -2- (=> Fig. A13-0160); re-adjust if necessary.
• ‒ Area -A-:
  Setting OK
• ‒ Area -B-:
  Wear zone
• ‒ Area -C-:
  Make new adjustment, or check belt drive including tensioner for wear.

Note:

If the end of the piston is in area -A-, this corresponds to a distance -D- of 25 ... 29 mm.

• ‒ → Counter-hold toothed belt tensioner with pin wrench -B- and tighten securing bolt -3-.
• ‒ Install crankshaft pulley.
• ‒ Install toothed belt guard (top section).
• ‒ Install ribbed belt and ribbed belt tensioning element => Page 13-19.
• ‒ Check ignition timing and adjust if necessary:

=> Motronic injection and ignition system (4-cylinder); Repair Group 28; Checking distributor ignition system (ADP engine); Checking and adjusting basic setting of distributor

Tightening torques

    1)    Bolt strength rating 10.9