Audi Workshop Service and Repair Manuals

Removing and installing toothed belt Special tools and workshop equipment required

t  Locking pin -T40011-

Removing l  Lock carrier must be in service position → Rep. Gr.50. –  Release quick-release fasteners and remove engine cover panel -arrows-. –  Remove poly V-belt and tensioner for poly V-belt → Chapter. –  Remove viscous fan → Chapter.

–  Remove toothed belt cover (top section)   Caution Irreparable damage can be caused if the toothed belt slips. Turn crankshaft only in direction of engine rotation (in clockwise direction). –  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-. –  Remove vibration damper → Chapter.

–  Remove toothed belt cover (bottom section) -arrows-.

Caution Risk of damage to toothed belt tensioner. The toothed belt tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure. –  Applying constant and moderate force, apply hexagon key through opening -2- to press toothed belt tensioning roller -1- anti-clockwise -arrow- until piston can be locked with locking pin -T40011-. –  Insert locking pin -T40011- and make sure that it remains in place. –  Mark rotation direction of toothed belt with chalk or felt-tip pen and remove toothed belt.   Note Bolt -3- must not be slackened. 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.

–  Align markings on camshaft sprocket/cylinder head cover -top arrow-. –  Fit toothed belt on crankshaft sprocket (note rotation direction). –  Install toothed belt cover (bottom section). –  Secure vibration damper with one bolt (note fixing arrangement). –  Rotate crankshaft to “TDC”-bottom arrow- by turning bolt for toothed belt sprocket. –  Fit toothed belt onto tensioning roller and camshaft sprocket.

–  Applying constant and moderate force, apply hexagon key to press toothed belt tensioning roller -1- anti-clockwise -arrow- until locking pin -T40011- can be pulled out.

–  Turn crankshaft two rotations by turning bolt for toothed belt sprocket until the crankshaft is at “TDC” again. l  Marking on camshaft sprocket and marking on crankshaft must be aligned to “TDC”-arrows-. –  Install vibration damper → Chapter. –  Install toothed belt cover (top section). –  Install viscous fan → Chapter. –  Install poly V-belt and tensioner for poly V-belt → Chapter. Tightening torques → Chapter