Audi Workshop Service and Repair Manuals

Removing and installing toothed belt Special tools and workshop equipment required

t  Locking pin -T40011-

Removing –  On vehicles with auxiliary/additional heater, remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-fasteners -1- and -2- and take off front noise insulation. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50.

–  Pull off engine cover panel -arrows-.   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. –  Remove poly V-belt.

–  Unscrew bolts -arrows- and remove poly V-belt tensioner together with engine lifting eye.

–  Remove toothed belt cover (top section) -arrows-.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Rotate crankshaft to TDC by turning central bolt for toothed belt sprocket. l  Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC -arrows-.

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

–  Remove toothed belt cover (centre and bottom) -arrows-. –  Mark direction of rotation of toothed belt with chalk or felt pen.   Caution t  The toothed belt tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure. t  To avoid damage, do not apply more force than necessary when compressing the toothed belt tensioner.

–  Applying constant and moderate force, use hexagon key to press toothed belt tensioner clockwise in direction of -arrow- until piston in tensioner/damper can be locked with locking pin -T40011-. –  Unscrew dowel bolt -1- and remove tensioning roller with washer. –  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. –  Fit toothed belt onto crankshaft sprocket, noting direction of rotation. –  Install toothed belt cover (bottom) -arrows-.   Note

The vibration damper can only be installed in one position: the hole -arrow- in the vibration damper must fit over the projection on the toothed belt sprocket on the crankshaft.

–  Align markings on camshaft sprocket / toothed belt cover (rear) and markings on vibration damper / toothed belt cover (bottom) -arrows-. –  Fit toothed belt onto remaining sprockets.

–  Fit dowel bolt -1- with washer in tensioning roller and tighten dowel bolt. –  Applying constant and moderate force, use hexagon key to press toothed belt tensioner clockwise in direction of -arrow- and pull out locking pin -T40011-.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Turn crankshaft two rotations via central bolt for toothed belt sprocket until it is positioned at TDC again. l  Make sure that the engine is rotated without stopping during the final 45° (1/8 turn) of the crankshaft. –  Check valve timing again: l  Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC -arrows-. If the markings do not align: –  Repeat adjustment of valve timing.

If the markings align: –  Install toothed belt cover (centre) -arrows-.

–  Install top section of toothed belt cover (make sure it engages securely on centre section of toothed belt cover). –  Tighten bolts -arrows-.

–  Install tensioner for poly V-belt together with engine lifting eye -arrows-. Installation is carried out in the reverse order; note the following: –  Install poly V-belt → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. Tightening torques

Component	Nm
Tensioning roller to retaining plate	40
Toothed belt cover (bottom and centre section) to cylinder block	10 1)
Vibration damper to toothed belt sprocket	10 + 90° 2)3)
Toothed belt cover (top section) to cylinder head	10
Tensioner for poly V-belt to bracket for ancillaries	23
l  1) Install using locking fluid; for locking fluid refer to → Parts catalogue. l  2) Renew bolts. l  3) 90° = one quarter turn.