Audi Workshop Service and Repair Manuals

Special tools,
testers and auxiliary items required

• ◆ Special tool 2065 A
• ◆ Special tool 3036
• ◆ Special tool 3359
• ◆ Special tool Matra V/159

• ● Engine in vehicle
• ● Lock carrier must be in service position .

Removing

• ‒ → Remove engine cover panel -arrows-.
• ‒ Removing toothed belt => Page 13-19
• ‒ Remove viscous fan (with belt pulley) => Page 13-13.
• ‒ Install ribbed belt tensioner => Page 13-7.

• ‒ → Remove bolts -3- and detach cover -2-.
• ‒ Place solenoid valve for boost pressure control-1- to one side with hoses connected.

• ‒ → Unbolt vibration damper.

• ‒ → Remove upper and bottom section of toothed belt guard -arrows-.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with manual gearbox).

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with automatic gearbox).

Note:

With engine removed turn crankshaft to TDC No. 1 cylinder=> Page 13-59.

• ‒ Remove cylinder head cover => Page 15-8.

• ‒ → Lock camshaft with setting bar 2065 A.
• ‒ Align setting bar as follows:
  Turn arrested camshaft so that one end of setting bar contacts cylinder head. Measure the gap at other end of setting bar using a feeler gauge. Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn camshaft until setting bar contacts feeler gauge. Insert a 2nd feeler gauge of same thickness at other end, between setting bar and the cylinder head.

• ‒ → Lock injection pump sprocket with setting pin 3359.
• ‒ Remove securing bolts -arrows- of injection pump sprocket.

Note:

→ Do not loosen central nut -2- of injection pump sprocket. Otherwise the injection pump basic setting is maladjusted and can no longer be corrected using workshop tools.

• ‒ Mark direction of rotation of belt with chalk or felt pen.
• ‒ Remove tensioner.
• ‒ Remove idler wheel.
• ‒ Take off toothed belt.

Installing (adjust valve timing)

• ● Camshaft locked with setting bar.
• ● Injection pump locked with setting pin 3359.

Notes:

• ◆ The position of the toothed belt must be set as described below, even after repairs in which the belt is only taken off the camshaft sprocket.
• ◆ When turning the camshaft, the crankshaft must not be at TDC at any cylinder. Danger of damage valves/piston crown.
• ◆ Never use setting bar to counterhold when loosening and tightening camshaft sprocket. Counterhold with 3036.

• ◆ → Replace securing bolts -1- of injection pump sprocket.

• ‒ → Loosen securing bolt of camshaft sprocket by 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through hole of rear toothed belt guard).
• ‒ Centre the injection pump sprocket in the slots.
• ‒ Check again whether TDC mark on flywheel and reference mark are aligned.
• ‒ Place toothed belt on crankshaft sprocket, intermediate shaft, injection pump sprocket and tensioner (note direction of rotation).
• ‒ Install camshaft sprocket together with toothed belt and position with securing bolt (camshaft sprocket can still be turned).
• ‒ Install the idler wheel.

• ‒ → Turn tensioner eccentric clockwise using nut driver (e.g. Matra V/159) until notch and lobe -arrows- are aligned.

Note:

If eccentric has been turned too far clockwise during tensioning, tensioner must then be fully released. Then turn eccentric clockwise again to tension.

• ‒ Tighten lock nut on tensioner to 20 Nm.
• ‒ Check again whether TDC mark on flywheel and reference mark are aligned.
• ‒ Tighten securing bolt for camshaft sprocket to 45 Nm.

Note:

Never use setting bar to counterhold when loosening and tightening camshaft sprocket. Counterhold with 3036.

• ‒ Tighten new securing bolts for injection pump sprocket initially to 20 Nm.

Notes:

• ◆ After injection start dynamic test, bolts must be tightened by a 1/4 (90°) turn.
• ◆ The securing bolts are stretch bolts and cannot be re-used. Once tightened to correct torque (20 Nm + 90°), they must be replaced after loosening.

• ‒ Remove setting bar 2065 A from camshaft and setting pin 3359 from injection pump sprocket.

• ‒ Turn crankshaft a further two rotations in direction of engine rotation and reset to TDC No. 1 cylinder.

• ‒ → Check tension of toothed belt.
• ‒ Markings -arrows- must be aligned.
• ‒ If necessary retighten toothed belt.
• ‒ Check if injection pump sprocket can be locked with pin 3359.
• ‒ Check position of camshaft with setting bar 2065 A.

Notes:

• ◆ If it is not possible to insert setting bar, repeat adjustment.

• ◆ If setting pin 3359 cannot be inserted:

• ‒ → Loosen securing bolts -arrows- of injection pump sprocket.
• ‒ Rotate injection pump sprocket hub until setting pin fits.
• ‒ Retighten securing bolts for injection pump sprocket to 20 Nm.

• ‒ Install viscous fan=> Page 13-13.

• ‒ Install ribbed belt .
• ‒ Dynamically check commencement of injection

=> Diesel direction-injection and glow lamp system (4-cyl.) 07.97 ä; Repair group 23; Servicing diesel direct injection system; Dynamically checking and adjusting commencement of injection

Tightening torques

    1)    Stretch bolts - renew

    2)    90°corresponds to a quarter turn