Audi Workshop Service and Repair Manuals

Removing and installing toothed belt - vehicles up to 07.2000 Special tools and workshop equipment required

t  Tensioning bolt -T10092-

t  Locking pin -T40011-

Removing –  Release quick-release fasteners and remove engine cover panel -arrows-. –  Move lock carrier to service position → Rep. Gr.50. –  Remove poly V-belt → Chapter. –  Remove tensioner for poly V-belt → Chapter „Removing and installing bracket for ancillaries“. –  Remove viscous fan → Chapter.

–  Remove toothed belt cover (top section)   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-.

–  Counterhold by applying ring spanner to bolt for toothed belt sprocket and unbolt vibration damper.

–  Remove centre and bottom sections of toothed belt cover -arrows-.

–  Screw tensioning bolt -T10092- into toothed belt tensioner. –  Compress piston of tensioner just far enough so that the piston can be locked with locking pin -T40011-. –  Mark rotation direction of toothed belt with chalk or felt-tip pen and 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.

–  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 coolant pump, then onto tensioning roller, and finally onto camshaft sprocket.

–  Remove tensioning bolt -T10092-. –  Remove locking pin -T40011- from tensioner, so that piston of tensioner is released.

–  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 viscous fan → Chapter. –  Install poly V-belt tensioner → Chapter „Removing and installing bracket for ancillaries“. –  Install poly V-belt → Chapter.

–  Install lock carrier with attachments → 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-. Tightening torques

Component	Nm
Toothed belt cover (bottom and centre section) to cylinder block	10 1)
Stop for torque reaction support to sump	28
l  1) Install using locking fluid; for locking fluid refer to → Parts catalogue.