Audi Workshop Service and Repair Manuals

Removing and installing toothed belt

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Adapter -10 - 222 A /13-

t	Diesel injection pump locking pin -3359-

t	Pin wrench -3387-

t	Hose clip pliers -V.A.G 1921-

t	Crankshaft stop -T10050-

t	Locking pin -T10115-

t	Counterhold tool -T10172- with pin -T10172/4-

t	Adapter -T40093/6- from engine support bracket (supplementary set) -T40093-

t	Locking fluid → Parts catalogue

Removing –  Remove front right wheel. –  Remove noise insulation -arrows-. –  Remove poly V-belt → Chapter.

–  Remove bonnet → Chapter. –  If fitted, unclip bracket -1-. –  Take off engine cover panel -arrows-. –  Remove noise insulation beneath cover.

–  Lever off caps -3 and 4- on two-piece windscreen wiper arm with a screwdriver. –  Slacken nuts on two-piece windscreen wiper arm a few turns. –  Release arms -1 and 2- one after the other by tilting them slightly on the wiper shafts. –  Remove nuts completely and take off two-piece windscreen wiper arm.   Note Use puller (commercially available) to remove wiper arm if necessary.

–  Disconnect washer fluid hose -3-. –  If fitted, unplug electrical connectors -4 and 5- for heated washer jets. –  Open hose clip -6- using hose clip pliers -V.A.G 1921- and detach water drain hose from cowl panel grille. –  Pull off rubber seal -1- on cowl panel grille. –  Disconnect cowl panel grille -2-. –  Move washer fluid hose clear.

–  Unscrew nuts and bolts -arrows-. –  Pull fresh air duct forwards and remove by turning it to right side of vehicle.

–  Detach air hose -1- from intake manifold; to do this, release retaining clip -2--arrow-, if fitted.

Vehicles with engine code letters AMF, BHC: –  Detach resonator from air pipe -arrow-.

All models: –  Unplug electrical connector -2- at air mass meter -G70-. –  Detach vacuum hose -1-. –  Release hose clip -4- and remove air pipe with air mass meter -G70-.   Note Disregard -item 3-.

–  Unscrew poly V-belt tensioner -arrows-.

–  Remove toothed belt cover (top section) -arrows-.

–  Unbolt vibration damper; counterhold on centre bolt with ring spanner.

–  Unbolt toothed belt cover (centre and bottom) -arrows-.

–  Remove bottom bolt -1- for engine support.   Note Bolts -2- and -3- do not have to be loosened at this stage.

–  Set up support bracket -10 - 222 A- with adapters -10 - 222 A /13- and adapter -T40093/6- on wing panel flanges.   Caution At the same time, engage adapter -10 - 222 A /13- in mountings for bonnet -arrow-. l  Remove clamping bolt in adapter -T40093/6-. l  Adapter -T40093/6- is fitted with its arm pointing upwards. –  Attach hook on spindle -10 - 222 A /11- to engine lifting eye. –  Take up weight of engine using spindle (but do not raise engine).

Vehicles with cover for engine mounting –  Remove cover for engine mounting by unscrewing bolts -1 and 2-.

–  Remove bolts -1 and 3- and detach support arm with engine mounting -2-.

Vehicles without cover for engine mounting   Note Do not loosen nut -3- unless renewing engine mounting. –  Remove bolts -1 and 2- and detach support arm with engine mounting.

All models: –  Remove top bolts -2- and -3- and detach engine support.   Note Disregard -item 1-.

Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).   Note Turn over the engine at the central bolt on the crankshaft. –  Turn the crankshaft to “TDC”. l  The space between the two lugs on sender wheel of camshaft must align with marking “3Z” on toothed belt cover (rear) -arrows-. –  Lock hub on camshaft with locking pin -3359-. –  Lock crankshaft sprocket with crankshaft stop -T10050-.   Note The crankshaft stop can only be pushed onto the sprocket from the front face of the teeth. l  The markings on the toothed belt sprocket and the crankshaft stop -T10050- must align. The pin of the crankshaft stop -T10050- must engage in the aperture in the sealing flange.

–  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. –  Using 2-hole pin wrench -3387- turn eccentric adjuster on belt tensioner anti-clockwise -arrow- until it is possible to lock tensioning roller into position with locking pin -T10115-.   Note Instead of using the 2-hole pin wrench -3387-, you can also use the special tool Matra V/159.

–  Turn 2-hole pin wrench -3387- 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  Camshaft locked with locking pin -3359-. l  Crankshaft locked in position with crankshaft stop -T10050-. l  Tensioning roller 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 first onto camshaft sprocket, tensioning roller, crankshaft sprocket and then onto coolant pump sprocket.

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 -3387- until pointer -2- aligns with the centre of the slot on the base plate.   Note Make sure that the securing nut does not also turn. –  Hold tensioning roller in this position and tighten securing nut to 20 Nm + 45° (1/8 turn).   Note When tightening the securing nut, the pointer 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 -3359- and crankshaft stop -T10050-.

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 it is again positioned just before “TDC”. –  Lock the hub into place with the locking pin -3359- when turning. l  The space between the two lugs on sender wheel of camshaft must align with marking “3Z” on toothed belt cover (rear) -arrows-.   Note For illustration purposes, the camshaft sprocket is shown with the toothed belt removed. –  Check whether: l  The crankshaft can be locked with the crankshaft stop -T10050-. 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 -arrows- of camshaft sprocket.

–  Turn the crankshaft slightly further in the normal direction of rotation until it can be locked with crankshaft stop -T10050-.   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 -3359- and crankshaft stop -T10050-.   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 at “TDC” again. –  Check valve timing once again → Anchor. Assembling: Installation is carried out in the reverse order; note the following:   Note Hose connections and hoses for charge air system must be free of oil and grease before assembly. Do NOT use lubricant. –  Install toothed belt cover (bottom and centre). –  Install vibration damper → Chapter. –  Install support arm with engine mounting → Chapter. –  Fit toothed belt cover (top section). –  Install air pipes/hoses with plug-in connectors → Chapter. –  Install poly V-belt → Chapter. –  Install windscreen wiper arm → Rep. Gr.92. Tightening torques

Component	Nm
Camshaft sprocket to hub	25
Tensioning roller for toothed belt to cylinder head	20 + 45° 1)
Toothed belt cover (bottom) to cylinder block	10 2)
Toothed belt cover (centre) to cylinder block	10 2)
Engine support to cylinder block	45
Tensioner for poly V-belt to bracket for ancillaries	22
Engine cover panel to bracket	5.5
l  1) 45° = one eighth turn. l  2) Install using locking fluid; refer to → Parts catalogue.