Audi Workshop Service and Repair Manuals

Removing toothed belt from camshaft sprockets

t	Locking pin -T40011-

t	Counterhold tool -3036-

t	Socket (22 mm) -3078-

t	Locking pin -3242-

t	Diesel injection pump locking pin -3359-

t	Camshaft clamp -3458-

t  Two-arm puller -T40001-

Removing –  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Open quick-release fasteners -1 … 3- and take off front and rear 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-.

–  Unscrew viscous fan (32 mm).

–  Release fasteners -arrows- and remove toothed belt cover (left and right).

–  Remove poly V-belt cover -arrows-.   Note Watch position of spacer sleeves for poly V-belt cover.

–  Turn the crankshaft to TDC.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).   Note Turn over the engine at the central bolt on the crankshaft. –  Rotate crankshaft until the smaller drilling -1- of the two drillings on the vibration damper is positioned at the top. –  Lock injection pump sprocket with locking pin -3359-. l  It must be possible to insert locking pin -3359- into drilling on injection pump; rotate crankshaft slightly in both directions if necessary.

–  Unscrew plug for TDC marking from cylinder block.   Note There is a TDC drilling in the crankshaft directly behind the plug (it is possible to feel the hole).   WARNING To avoid any risk of injury, do not rotate the crankshaft while feeling for the TDC hole with your finger. –  Screw locking pin -3242- into threaded hole where plug has been removed, and tighten.

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at expansion tank (bottom) and move expansion tank to one side (coolant hoses -1 ... 3- remain attached).

–  Remove bolts -1- for exhauster pump on cylinder head (left-side) and turn pump in direction of -arrow-. –  Move exhauster pump to side (hose remains attached).

–  Unplug electrical connector -1-. –  Slacken hose clip -2-. –  Pull hose -3- off air cleaner housing. –  Unscrew bolt -4- and remove air cleaner housing. –  Unscrew nuts and detach fuel filter together with bracket from bulkhead.   Note Fuel hoses remain connected.

–  Remove air intake pipe between turbocharger and charge air cooler (right-side) -arrows-.

–  Using a screwdriver, lever off sealing cap -arrow- on cylinder head (right-side).   Note t  Removal destroys sealing cap. t  Take care not to damage sealing surfaces.

–  Insert camshaft clamps -3458- in both cylinder heads, and secure them with the chain to prevent them dropping out.   Caution Do not use camshaft clamps -3458- as counterhold tools.   Note

Before removing, mark rotation direction of toothed belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Slacken toothed belt tensioner and take toothed belt off camshaft sprocket.

–  Unbolt drive sprocket -1- for injection pump from camshaft sprocket -arrows-.   Caution Do not use camshaft clamp -3458- as a counterhold tool.

–  Loosen both camshaft sprocket bolts using counterhold tool -3036-.   Note Leave bolts screwed in loosely.

–  Detach cover cap at bottom right of bracket for viscous fan. –  Turn toothed belt tensioning roller in direction of -arrow- using an 8 mm Allen key until tensioning lever of tensioner is compressed far enough to allow locking pin -T40011- to be inserted into the hole and the plunger.   Note The toothed belt tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure.

–  Pull camshaft sprockets (left and right) off their tapers using two-arm puller -T40001- with claws -T40001/2-. –  Unbolt camshaft sprocket (left-side) (cylinders 4 ... 6). –  Detach toothed belt from camshaft sprockets. Installing (adjusting valve timing) l  Camshafts locked in position with camshaft clamps -3458-. l  Crankshaft locked in position with locking pin -3242-. l  Camshaft sprockets free to turn. The valve timing must be adjusted as described below, even when the toothed belt has only been removed from the camshaft sprocket: l  The crankshaft must not be at “TDC” at any cylinder when the camshafts are turned. Otherwise there is a risk of damage to valves and piston crowns. l  Do not use camshaft clamps -3458- as counterhold tools. l  Adjustment can be performed with cold or warm engine.

–  Fit the toothed belt onto one of the camshaft sprockets. –  Take second camshaft sprocket, fit toothed belt and install sprocket on camshaft. –  Tighten the two camshaft sprocket bolts until the sprockets can still just be turned without axial movement.

–  Slacken belt tensioner using 8 mm Allen key -arrow- and pull out locking pin -T40011-.

–  Pre-tension toothed belt to 15 Nm by turning with torque wrench in direction of -arrow-.

–  Secure camshaft sprockets (counterhold using counterhold tool -3036-).   Caution Do not use camshaft clamps -3458- as counterhold tools.

–  Lock injection pump sprocket with diesel injection pump locking pin -3359-.

–  Fit drive sprocket for injection pump -1- so that it is aligned centrally in elongated holes. –  Tighten drive sprocket -arrows- until it is still just possible to turn it on the camshaft sprocket. –  Fit toothed belt for injection pump on sprockets. Pay attention to the direction of rotation as marked upon removal.

–  Tension toothed belt. To do so, turn Allen key anti-clockwise in direction of -arrow- until marks -1- coincide. –  Then tighten securing nut using socket (22 mm) -3078-.   Note Depending on version, pointer -1- may have no tip. –  Tighten bolts at camshaft sprocket. –  Remove diesel injection pump locking pin -3359-. –  Remove camshaft clamps -3458- from both cylinder heads. –  Remove locking pin -3242-. –  Turn crankshaft two rotations in normal direction of rotation until the crankshaft is at “TDC” again.

–  To check adjustment, screw locking pin -3242- into hole in cylinder block once again.

–  Check positions of camshafts with camshaft clamps -3458-. If it is not possible to insert the camshaft clamps, repeat adjustment. –  Remove camshaft clamps -3458- from both cylinder heads. –  Remove locking pin -3242-.

–  Check tension of toothed belt for injection pump. l  Marks -1- and -2- must be opposite one another.

–  Renew sealing cap (rear) on cylinder head (right-side). –  Using a suitable drift, knock in new sealing cap (core plug) -arrow- until flush. –  Install exhauster pump with new O-rings on cylinder head (left-side). –  Screw plug for the TDC mark into cylinder block with a new seal. Remaining installation steps are carried out in reverse sequence; note the following:   Note t  Renew seals and O-rings. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  Install viscous fan → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install bumper cover → General body repairs, exterior; Rep. Gr.63. –  Dynamically check and adjust commencement of injection → Rep. Gr.23. Tightening torques

Component	Nm
Camshaft sprocket to camshaft	75
Drive sprocket for injection pump to camshaft	22
Tensioning roller for injection-pump toothed belt to bracket for viscous fan	36
Exhauster pump to cylinder head	10
Screw plug in cylinder block	35
Hose clips (9 mm wide)	3
Hose clips (13 mm wide)	5.5