Audi Workshop Service and Repair Manuals

Removing and installing toothed belt (vehicles without separate toothed belt covers)   Note Vehicles from 01/2006 onwards are fitted with a new type of toothed belt cover. Identification: the top section of the toothed belt cover has no cap → Item and the toothed belt cover is divided near the engine support. Removing and installing toothed belt (vehicles with separate toothed belt covers) → Chapter. Special tools and workshop equipment required

t  Support bracket -10 - 222 A-

t  Shackle -10 - 222 A /12-

t  Pin wrench -T10020-

t  Locking pin -T10060A- Removing –  Detach engine cover panel with air cleaner → Rep. gr.24.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Remove noise insulation → Rep. gr.50.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-.

–  Unscrew bolts -1 ... 3- and remove pendulum support.

–  Unscrew bolts -arrows- and remove charge air pipe together with hoses. –  Drain off coolant → Chapter   WARNING Fuel supply line is pressurised. Wear safety goggles and protective clothing to avoid possible injury and skin contact. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Mark fuel line -1- and line going to ACF -2-. –  Disconnect fuel line -1-. –  Disconnect ACF line -2-. –  Disconnect ACF line going to tank -3-. –  Lift out ACF in -direction of arrow-.

–  Detach the coolant hose at the bracket -1-. –  Remove bracket for activated charcoal filter -arrows-.

–  Unbolt filler neck for windscreen washer reservoir -1-. –  Remove retaining clip; to do so, unscrew bolts -2 and 3-.

–  Unplug electrical connector -1- from coolant level indicator. –  Detach coolant expansion tank -arrows-.

–  Disconnect coolant pipe -arrow-. –  Remove poly-V belt and remove locking pin -T10060A- → Chapter.

–  Position support bracket -10 - 222 A- on bolted flanges of wing panels. The spindles face forwards. –  Attach hooks of spindles with shackles -10 - 222 A /12- to the lifting eyes.

–  Remove securing bolts from assembly mounting/engine support -arrows- and remove complete assembly mounting.   Caution When raising engine with support bracket -10-222A-, ensure that components/hoses are not damaged, strained or torn off.

–  Raise engine with support bracket -10-222A- until it is possible to loosen and remove the two top bolts -1 and 2- securing the engine support.

–  Set camshaft sprocket to TDC marking by turning crankshaft. Marking on camshaft sprocket must align with arrow on toothed belt cover.

–  Remove vibration damper / pulley.

–  Unscrew bolts from toothed belt cover (bottom) -arrows-.

–  Loosen bottom bolt -3- and remove engine support from below.

–  Unscrew remaining toothed belt cover bolts -arrows- and remove toothed belt cover from engine. –  Mark direction of rotation of toothed belt. –  Loosen tensioning roller and remove toothed belt. –  Turn crankshaft back slightly. Installing l  Tightening torques → Chapter   Note t  When turning the camshaft, the crankshaft must not be at TDC. Otherwise, there is a risk of damage to valves and piston crowns. t  The engine must be no more than warm to touch. –  Fit toothed belt on crankshaft sprocket (note rotation direction). –  Secure toothed belt cover (bottom section) with the two bolts at the bottom. –  Install vibration damper / pulley with new bolts.

–  Turn crankshaft and camshaft to TDC No. 1 cylinder -arrows-.

–  Fit toothed belt in the sequence: tensioning roller, camshaft sprocket, coolant pump and last onto idler roller -arrow-.   Note

Check tensioning roller is seated correctly in cylinder head.

–  Tension toothed belt. To do so, turn hexagon key at the eccentric adjuster clockwise (direction of arrow) until the notch is above the indicator. –  Then release tension on toothed belt. –  Now tension toothed belt until the notch and the indicator are aligned. –  Tighten securing nut –  Turn crankshaft two turns in direction of engine rotation and set again to TDC. Make sure that the engine is rotated without stopping during the final 45° (1/8 turn). –  Check tension of toothed belt again. Specification: indicator and notch must align.

–  Check valve timing again. If the markings do not align: –  Repeat adjustment of valve timing. If the markings align:

–  Install toothed belt cover -arrows-.   Note

Note different bolt lengths. Bolt -3- is approx. 25 mm shorter than bolts -1 and 2-.

–  Insert bottom securing bolt -3- in engine support. –  Install engine support on cylinder block from below and tighten bolt finger-tight. –  Raise engine with support bracket -10-222A- until it is possible to screw in the two top bolts -1 and 2-. –  Tighten all bolts. –  Lower the engine down to installation position.

–  Secure assembly mounting for engine to engine support -arrows-; to do so, bring surfaces into contact using support bracket -10-222A-. –  Remove support bracket -10-222A-. –  Attach fuel hoses onto connections. Make sure plug-in connectors are properly secured. –  Install coolant expansion tank. –  Connect battery → Electrical System; Rep. gr.27 –  Fit engine cover panel. –  Install crankshaft pulley → Chapter. –  Adjust engine mountings → Chapter. –  Install poly V-belt → Chapter. –  Install air pipes with plug-in connectors → Chapter. –  Bleed fuel system → Motronic direct injection and ignition system (4-cylinder); Rep. Gr. 24; Servicing fuel injection system. –  Install insulation tray.