Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Pin 3359
• ◆ V.A.G 1306
• ◆ VAS 5024 A
• ◆ Camshaft straightedge T10098
• ◆ Two-arm puller T40001

Removing

• ‒ → Remove oil dipstick -1- from guide tube.
• ‒ Unclip caps.
• ‒ Unscrew nuts -arrows- and remove engine cover.
• ‒ Reinsert oil dipstick in guide tube.

• ‒ Open the cover of the coolant expansion tank

• ‒ → Remove lower air duct pipe -arrows-.

• ‒ → Remove noise insulation in centre and on right -arrows-.

Note:

Mark the running direction with chalk or a felt-tipped pen before removing the ribbed belt. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

• ‒ Fit flat 16 mm ring spanner to hexagon of tensioner.
• ‒ → Swivel tensioning roller in direction of arrow to slacken ribbed belt.
• ‒ Remove ribbed belt.

• ‒ Place drip tray V.A.G 1306 below engine.
• ‒ → Turn drain plug -arrow- on radiator anti-clockwise. If necessary, fit drain hose on connection.

• ‒ → Also disconnect lower coolant hose on oil cooler -arrow-, and drain off remaining coolant.

• ‒ Detach the cover and the electrical connector at the right headlight unit.
• ‒ → Disconnect fuel-feed line -2- and fuel-return line -1- at injection pump.
• ‒ Disconnect the electrical connection -3- at the sender -G71/-G72.
• ‒ Expose the wiring at the air duct pipe.
• ‒ Remove the air duct pipe on right side -arrows-.

• ‒ → Remove tensioner for ribbed belt -arrows-.
• ‒ Remove upper toothed belt guard.

• ‒ → Remove air duct hose -1- from air duct pipe.
• ‒ Detach connector of air mass meter -3-.
• ‒ Unscrew bolts -4- and -5-.
• ‒ Remove vent hose -2- from rear of air cleaner housing.
• ‒ Take out air cleaner housing.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with manual gearbox).

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with automatic gearbox).

Note:

Position crankshaft to TDC No. 1 cylinder with engine removed.

• ‒ Remove the exhauster => Fig.15-8.
• ‒ → Turn the bolts -1- by hand up to stop into the cylinder head.
• ‒ Lock the camshaft using camshaft straightedge T10098 as shown in the illustration.
• ‒ If the camshaft straightedge T10098 cannot be inserted, rotate crankshaft 1 additional turn (360°).

• ‒ → Lock injection pump sprocket using pin 3359.
• ‒ Loosen injection pump sprocket securing bolts -arrows-.

Note:

→ Never loosen the injection pump sprocket centre nut -2-. Otherwise the injection pump basic setting is incorrectly adjusted and cannot be corrected again using workshop equipment.

• ‒ → Loosen the tensioning roller nut -arrow- by several turns.

• ‒ Remove the toothed belt from the camshaft toothed belt sprocket.
• ‒ → Unscrew the camshaft sprocket bolt by 1/2 turn .
• ‒ Place the two-arm puller T40001 with claw T40001/2 -Item A- and the two-arm claw T40001/3 -Item B- centralised onto the camshaft sprocket.
• ‒ Pull off the camshaft sprocket using the two-arm puller. Counterhold using an open-end spanner -C- in the process.
• ‒ Remove camshaft toothed belt sprocket.
• ‒ Remove the centre toothed belt guard.

Notes:

• ◆ The vibration damper and bottom toothed belt guard do not have to be removed.
• ◆ The toothed belt should be left in position on the crankshaft sprocket.

• ‒ → Unscrew the bolt -1- and lay the idler roller -2- downwards.
• ‒ Unscrew the bolts -3- and carefully guide the coolant pump -4- out towards rear between engine support and toothed belt guard.

Installing

Installation is carried out in the reverse order; note the following:

Notes:

• ◆ When performing installation procedures, replace seals and gaskets, as well as stretch bolts with specified tightening angle.
• ◆ Hose connections and hoses for charge air system must be free of oil and grease before assembly.
• ◆ Secure all hose connections with the correct hose clamps (same as original equipment):

=> Parts List

• ‒ Clean and smooth down sealing surface for O- ring as required.
• ‒ → Lightly coat new O-ring -5- with coolant G 012 A8 D.
• ‒ Fit coolant pump -4-.
• ‒ Installation position: Sealing plug in housing faces downwards.
• ‒ Tighten bolts -3- for coolant pump to 15 Nm.
• ‒ Replace idler roller bolt -1-, torque to 40 Nm and continue to turn 1/4 turn (90°).
• ‒ Install toothed belt (adjust valve timing) => Page 13-31.

Note:

Observe all instructions on removing and installing the toothed belt =>from Page 13-23.

• ‒ Install ribbed belt=> Page 13-10.
• ‒ Top up coolant => Page 19-7.

Tightening torques

    1)    Replace bolt

    2)    90°corresponds to a quarter of a turn