Audi Workshop Service and Repair Manuals

Removing:

• ‒ Remove ribbed belt .
• ‒ → Unscrew bolts -arrows- and remove engine cover panel -C-.

• ‒ → Remove pressure hoses -arrows- between charge air coolers and pressure pipes (left and right sides).

• ‒ → Remove pressure pipes -1-.

Note:

Watch position of retaining strips -2-.

• ‒ → Remove tensioner -1- for ribbed belt.
• ‒ Remove left and right toothed belt guards -2-.
• ‒ Remove centre toothed belt guard -3-.

• ‒ → Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.

Note:

Turn over the engine at the central bolt on the crankshaft.

• ‒ Check position of camshafts: the larger holes in the securing plates on the camshaft sprockets must align opposite one another on the inside. If this is not the case, turn crankshaft one revolution further.

• ‒ Remove sealing plug from cylinder block, left.

• ‒ The TDC drilling in the crankshaft must be visible (or able to be felt) in line with the sealing plug hole.

• ‒ → Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.

• ‒ → Remove vibration damper on crankshaft.

Note:

The central bolt does not have to be loosened to remove the vibration damper.

• ‒ → Remove idler wheel for ribbed belt
  -arrows-.
• ‒ Remove toothed belt guard behind vibration damper -arrows-.

Notes:

• ◆ Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when refitted.

• ◆ The toothed belt tensioning element is oil-damped and can therefore only be compressed slowly by applying constant pressure.

• ‒ → Using an 8 mm hexagon key, turn toothed belt tensioning roller -1- clockwise in direction of arrow until tensioning lever -2- compresses tensioning element -3- far enough to insert a special tool T40011 in the drilling and in the plunger.
• ‒ Insert special tool T40011 and release toothed belt tensioning roller.
• ‒ Take off toothed belt.

Installing

• ‒ Insert camshaft clamp 3391 in the securing plates of the two camshafts.
• ‒ Slacken both camshaft bolts and unscrew approx. 5 turns.
• ‒ Take out camshaft clamp 3391.
• ‒ → Pull off both camshaft sprockets with special tool T40001.
• ‒ Refit both camshaft sprockets with securing plates and tighten hand-tight again.

Note:

The camshaft sprockets should be just tight enough on the camshaft tapers so that they can still be turned but do not move axially.

• ‒ → Fit toothed belt on all sprockets as illustrated.
• ‒ Fit camshaft clamp 3391.

• ‒ → Using an 8 mm hexagon key, turn toothed belt tensioning roller -1- clockwise in direction of arrow until special tool T40011 can be removed.

• ‒ → Pre-tension the toothed belt by a turning in direction of arrow with a torque of 15 Nm using a torque wrench.
• ‒ Tighten bolts on camshaft sprockets.

• ‒ → Install idler wheel for ribbed belt -arrows-.
• ‒ Install toothed belt guard behind vibration damper -arrows-.

• ‒ → Install vibration damper. Note positions of locating lugs -arrows- on belt sprocket.

• ‒ Install toothed belt guard.
• ‒ Install ribbed belt => Page 13-3.

    1)    The central bolt must always be renewed.

    2)    Turning in two stages of 90°is also permissible.