Audi Workshop Service and Repair Manuals

Removing and installing toothed belt for high-pressure pump Special tools and workshop equipment required

t  Counterhold tool -3036-

t  Adapter -T40058- Removing –  Remove top section of intake manifold → Chapter.

–  Release hose clips -arrows-. –  Pivot toothed belt cover forward and disengage retaining pegs on bottom side of toothed belt cover. –  Remove toothed belt cover.   Note Before removing, mark rotation direction of toothed belt with chalk or felt-tip pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

–  Loosen bolt -arrow- for toothed belt tensioning roller approx. 2 turn.

–  Loosen central bolt -1- for toothed belt drive sprocket approx. 2 turns using counterhold tool -3036-.

–  Use puller -3032- to pull off toothed belt drive sprocket. –  Take off drive sprocket together with toothed belt. Installing Installation is carried out in the reverse order; note the following:

–  Check installation position of toothed belt tensioning roller: l  Retaining lug -arrow 2- must engage in slot on bracket for high-pressure pump. l  Tensioning roller must be slack and hexagon socket -arrow 1- must face downwards. –  Fit toothed belt together with toothed belt drive sprocket. –  Install toothed belt tensioning roller; to do so, screw in bolt for toothed belt tensioning roller without applying force until eccentric adjuster of toothed belt tensioning roller can just still be turned without axial movement. –  Screw in bolt for toothed belt drive sprocket until toothed belt drive sprocket can just still be turned without axial movement.

–  Tension toothed belt tensioning roller slightly by turning in direction of -arrow- using hexagon key until hexagon socket is in "1 o'clock" position.   Caution Do NOT turn tensioning roller up to or beyond „12 o'clock“ position.

–  Now release toothed belt tensioning roller -arrow- to such an extent that hexagon socket moves into "3 o'clock" position.

–  Tension tensioning roller slightly from "3 o'clock" position -arrow- until lug -1- and notch -2- are exactly in line.

–  Hold toothed belt tensioning roller in this position and tighten bolt -arrow- → Item.

–  Tighten bolt -1- for toothed belt drive sprocket using counterhold tool -3036- → Item.

–  Release fasteners -1 ... 4- and remove noise insulation panels.

–  Insert guide pin of adapter -T40058- as follows: l  The larger-diameter section -arrow 1- faces towards the engine. l  The smaller-diameter section -arrow 2- faces the adapter.

–  Turn crankshaft 1 rotation using adapter -T40058-.   Caution Irreparable damage can be caused if the camshaft timing chains slip. Turn crankshaft only in direction of engine rotation -arrow-.

–  Check toothed belt tension: l  Lug -1- should align with notch -2-. –  If the specification is not attained, re-adjust toothed belt tension. Installation is carried out in the reverse order; note the following: –  Install top section of intake manifold → Chapter.