Audi Workshop Service and Repair Manuals

Removing and installing poly V-belt pulley for crankshaft

Special tools and workshop equipment required

t	Spark plug socket and extension -3122 B-

t	Counterhold tool -3415- with pins -3415/1-

t	Dial gauge -VAS 6079-

t	Puller -T10094 A-

t	Adapter for dial gauge -T10170-

t	Locking pin -T10340-

Removing   Note t  Use locking pin -3415- in addition to counterhold tool -T10340- to prevent slipping and to make sure the tightening torque for the crankshaft pulley bolt is maintained. t  The locking pin -T10340- locks the crankshaft only in the direction of engine rotation.   Caution Risk of damage to engine. Locking pin -T10340- must be screwed in with crankshaft at „TDC“ position. –  Remove poly V-belt → Chapter.

–  Pull off engine cover panel (front) -arrows- and remove towards front.

–  Remove bolts -1 and 3-. –  Release hose clip -2-, detach air pipe (top right) and remove air hose.

–  Unplug electrical connector -2-. –  Detach vacuum hoses -1-.

–  Unplug electrical connector -4-. –  Remove bolts -1 and 3-. –  Press release tabs and disconnect crankcase breather hoses -arrows-. –  Release hose clip -2- and disconnect hose at activated charcoal filter. –  Detach hoses.

–  Apply puller -T10094 A- to ignition coil for cylinder 1, pull out ignition coil and at the same time unplug electrical connector at ignition coil for cylinder 1. –  Remove spark plug for cylinder 1 with spark plug socket and extension -3122 B-.

–  Screw adapter for dial gauge -T10170- into spark plug hole as far as the stop. –  Insert dial gauge -VAS 6079- with extension -T10170/1- as far as the stop and secure using locking nut -arrow-. –  Rotate crankshaft in normal direction of rotation to „TDC“. l  „TDC“ = maximum measured value on dial gauge.

–  Unscrew plug -arrow- for „TDC“ hole on cylinder block.

–  Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 Nm.   Note The locking pin -T10340- locks the crankshaft only in the direction of engine rotation. –  Remove front wheel housing liner (right-side) → Rep. gr.66.

Caution Risk of damage to engine. To prevent the crankshaft chain sprocket from slipping off the drive lug, do not rotate the crankshaft after the poly V-belt pulley has been detached. –  Loosen bolt for poly V-belt pulley using counterhold tool -3415- with pin -3415/1-. –  Remove bolt and take off poly V-belt pulley. Installing l  Tightening torques → Chapter „Poly V-belt drive - exploded view“   Note t  Renew the bolts tightened with specified tightening angle. t  All contact surfaces between bolt, poly V-belt pulley, bearing bush and chain sprocket must be free of oil and grease. –  Fit poly V-belt pulley, lubricate threads of bolt for poly V-belt pulley with oil and screw in by hand until bolt makes contact.   Caution Risk of damage to engine. t  Use dial gauge to check „TDC“ position of crankshaft. Crankshaft must only be brought into contact with locking pin -T10340- from „TDC“ position. t  Also use counterhold tool -3415- and pin -3415/1- to counterhold poly V-belt pulley when tightening bolt.

–  Turn crankshaft in direction of engine rotation until it makes contact with locking pin -T10340-. –  Tighten bolt for poly V-belt pulley (counterhold with counterhold tool -3415- and pin -3415/1-).

–  Remove locking pin -T10340-. Remaining installation steps are carried out in reverse sequence; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Install spark plug → Booklet819. –  Tighten plug for „TDC“ drilling → Fig.. –  Install air pipe (top right) → Chapter. –  Install air hoses with screw-type clips → Fig.. –  Install poly V-belt → Chapter.