Audi Workshop Service and Repair Manuals

Removing, installing and tensioning toothed belt

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1331-

t	Pin wrench -3387-

t	Locking plate -T10008-

t	Torque wrench -V.A.G 1332-

Removing –  Move lock carrier to service position → Chapter. –  Release quick fasteners -arrows- and remove engine cover panel.   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.

–  Remove toothed belt cover (top).   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise). –  Rotate crankshaft to TDC by turning bolt for toothed belt sprocket. l  Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC -arrows-.

–  Unscrew vibration damper and remove.

–  Remove toothed belt cover (centre and bottom) -arrows-.   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 anti-clockwise in direction of -arrow- until piston of tensioner can be locked with locking plate -T10008-. –  Insert locking plate -T10008- and make sure that it remains in place.   Note

Do not to bend limit stop -A- of eccentric adjuster. –  To slacken toothed belt, loosen nut -1- on tensioning roller and turn eccentric adjuster clockwise -arrow- using pin wrench -3387-. –  Mark direction of rotation of toothed belt with chalk or felt pen. –  Remove toothed belt. Installing (adjusting valve timing)   Note t  The toothed belt adjustment must also be performed as described below, even if the toothed belt has only been removed from the camshaft sprocket. 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. –  Fit toothed belt on crankshaft sprocket (note rotation direction). –  Install bottom toothed belt cover.   Note

The vibration damper/ pulley 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. –  Secure vibration damper/ pulley. Note positive location -arrow-.

–  Align markings on camshaft sprocket / cylinder head cover and markings on vibration damper / toothed belt cover -arrows-. –  Make sure that toothed belt tensioner is still locked with locking plate -T10008-. –  Fit toothed belt onto coolant pump, then tensioning roller, and finally camshaft sprocket.

Tensioning toothed belt   Note Do not to bend limit stop -A- of eccentric adjuster. –  Turn eccentric adjuster anti-clockwise onto stop in direction of -arrow- using pin wrench -3387-. –  Hold eccentric adjuster in this position and pull out locking plate -T10008-.

–  Turn eccentric adjuster clockwise in direction of -arrow- until gauge -2- with dimension -a- = 8 mm (e.g. drill bit) can be pulled through between tensioning lever and housing of tensioner. –  Hold eccentric adjuster in this position and tighten nut -1- of tensioning roller to 27 Nm.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Turn crankshaft two rotations via toothed belt sprocket bolt until it is positioned at TDC again. l  Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC -arrows-.

–  Use gauge -2- (e.g. drill bit) to check dimension -a- between tensioning lever and housing of tensioner. l  Dimension -a- = 6 ... 10 mm.

If dimension -a- is not attained:   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 anti-clockwise in direction of -arrow- until piston of tensioner can be locked with locking plate -T10008-.

–  Loosen nut -1- for tensioning roller. –  Tension toothed belt → Anchor. When dimension -a- is achieved: –  Fit centre and top section of toothed belt cover.

Assembling Installation is carried out in the reverse order; note the following: –  Install poly V-belt tensioner -arrows-. –  Install poly V-belt → Chapter. –  Install top section of toothed belt cover (make sure it engages securely on centre section of toothed belt cover).

–  Install lock carrier with attachments → General body repairs, exterior; Rep. gr.50. –  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten nuts -arrows-. –  Install front bumper cover → General body repairs, exterior; Rep. gr.63. –  Check headlight adjustment → Booklet8E. Tightening torques

Component	Nm
Tensioning roller to cylinder head	27
Vibration damper to toothed belt sprocket	10 + 90° → Remark → Remark
Toothed belt cover (bottom and centre section) to cylinder block	10 → Remark
Tensioner for poly V-belt to bracket for ancillaries	23
Stop for torque reaction support to lock carrier	28

1)  Install using locking fluid → Parts catalogue 2)  Renew bolts. 3)  90° equals a 1/4 turn.