Audi Workshop Service and Repair Manuals

Removing and installing toothed belt

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	2-hole pin wrench -T10020-

t	Mud wing compensation plate -T40045-

Removing –  Take off engine cover panel -arrows-.

–  Detach coolant expansion tank -1-, power steering reservoir -2- and activated charcoal filter -3-. Hoses remain connected.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt.

–  Lock poly V-belt tensioner using locking pin -T10060 A-. –  Remove poly V-belt.

–  Remove splash plate -2- and tensioning element -1- for poly V-belt.

–  Turn quick-release fastener -item 1- 90° anti-clockwise. –  Raise retaining tabs -arrows- and detach upper toothed belt cover.

–  Remove noise insulation panels (centre and right) -arrows-.

–  Turn crankshaft at central bolt on crankshaft sprocket in direction of engine rotation to TDC mark -arrows-.

l  At the same time the marking on front of the camshaft sprocket must align with the marking on the rear toothed belt cover -arrows-. –  Rotate crankshaft one turn further if necessary.

–  Unbolt crankshaft pulley.   Note To loosen and tighten the crankshaft pulley, counterhold central bolt with a ring spanner.

–  Unbolt lower and centre toothed belt covers -arrows-.

–  Remove the rubber sealing strip from the edges of the wing mounting flanges. –  Place compensation plates -T40045- between the wing mounting flange and the body panel underneath, so that the support bracket -10-222 A- does not damage the wing mounting flanges.

–  Set up support bracket -10-222 A- on wing panel flanges. l  The spindles face forwards. –  Detach crankcase breather hose from oil filler neck. –  Attach hooks of spindles to lifting eyes. –  Take up weight of engine evenly with both spindles (but do not raise engine).

–  Remove bolts -arrows- and detach connecting bracket, engine support and engine mounting.

–  Remove bolts -1 ... 3- and detach engine support.   Note To slacken the bolts for the engine support, raise or lower the engine slightly as necessary via the spindles on engine support bracket -10-222 A-.

–  Mark the rotation direction of toothed belt with chalk or a felt-tipped pen. –  Loosen nut on tensioning roller -arrow- several turns. –  Remove toothed belt.

Installing (adjusting valve timing)   Note When turning the camshaft, the crankshaft must not be at TDC. Otherwise, there is a risk of damage to valves and piston crowns. –  Align mark on camshaft sprocket with mark on toothed belt cover -arrows-. –  Fit toothed belt onto crankshaft sprocket, noting direction of rotation. –  Install bottom toothed belt cover.

–  Secure pulley with bolt, noting fixing arrangement. –  Check again whether the crankshaft is positioned at TDC -arrows-. –  Fit toothed belt in the sequence: coolant pump, tensioning roller, camshaft sprocket.

–  Note correct position of semi-automatic tensioning roller. l  Retaining lug -arrow- must engage in slot on cylinder head.

–  Turn tensioning roller at eccentric adjuster to stop in -direction of arrow- using 2-hole pin wrench -T10020-. –  Slacken tensioning roller until pointer -2- is approx. 10 mm below the notch -1-. –  Again, turn tensioning roller at eccentric adjuster to stop in -direction of arrow-. –  Slacken tensioning roller again until pointer -2- is approx. 10 mm below the notch -1-. –  Then tension tensioning roller until pointer -2- and notch -1- are back in line. –  Tighten securing nut –  Turn crankshaft at central bolt on crankshaft sprocket two revolutions in direction of engine rotation and check whether camshaft and crankshaft markings align at TDC with their respective reference points. –  Check again whether toothed belt is tensioned properly, repeat adjustment procedure if necessary. –  Install toothed belt cover.

Remaining installation steps are carried out in reverse sequence; note the following: Secure the engine support as follows: –  Initially screw bolts -1 ... 3- in finger-tight. –  Then tighten bolts -1 ... 3-. –  Install engine mounting. –  Install crankshaft pulley → Anchor. –  Adjust engine mountings → Chapter. –  Install poly V-belt → Chapter. –  Secure coolant expansion tank, power steering reservoir and activated charcoal filter. Tightening torques

Component	Nm
Toothed belt tensioning roller to cylinder head	23
Toothed belt cover (bottom) to cylinder block	10 1)
Toothed belt cover (centre) to cylinder block	10 1)
Engine support to cylinder block	45
Engine mounting to body	40 + 90° 2)3)
Connecting bracket to body/engine mounting	25
Tensioner for poly V-belt to bracket for ancillaries	23
Splash plate to bracket for ancillaries	23
l  1) Install using locking fluid; locking fluid → Parts catalogue. l  2) Renew bolts. l  3) 90° = one quarter turn.