Audi Workshop Service and Repair Manuals

Detaching toothed belt from camshaft sprocket Special tools and workshop equipment required

t  Locking pin -T40011-

Removing –  On vehicles with auxiliary/additional heater, remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-fasteners -1- and -2- and take off front 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-.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt. –  Remove poly V-belt.

–  Unscrew bolts -arrows- and remove poly V-belt tensioner together with engine lifting eye.

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

–  Remove toothed belt cover (centre) -arrows-.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Rotate crankshaft to TDC by turning central bolt for toothed belt sprocket. l  Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC -arrows-.   Caution t  The toothed belt tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure. t  To avoid damage, do not apply more force than necessary when compressing the toothed belt tensioner.

–  Applying constant and moderate force, use hexagon key to press toothed belt tensioner clockwise in direction of -arrow- until piston in tensioner/damper can be locked with locking pin -T40011-. –  Unscrew dowel bolt -1- and remove tensioning roller with washer. –  Remove toothed belt from camshaft sprocket.

Fitting toothed belt –  Align markings on camshaft sprocket / toothed belt cover (rear) and markings on vibration damper / toothed belt cover (bottom) -arrows-. –  Fit toothed belt onto sprockets.

–  Fit dowel bolt -1- with washer in tensioning roller and tighten dowel bolt. –  Applying constant and moderate force, use hexagon key to press toothed belt tensioner clockwise in direction of -arrow- and pull out locking pin -T40011-.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Turn crankshaft two rotations via central bolt for toothed belt sprocket until it is positioned at TDC again. l  Make sure that the engine is rotated without stopping during the final 45° (1/8 turn) of the crankshaft. –  Check valve timing again: l  Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC -arrows-. If the markings do not align: –  Repeat adjustment of valve timing.

If the markings align: –  Install toothed belt cover (centre) -arrows-.

–  Install top section of toothed belt cover (make sure it engages securely on centre section of toothed belt cover). –  Tighten bolts -arrows-.

–  Install tensioner for poly V-belt together with engine lifting eye -arrows-. Remaining installation steps are carried out in reverse sequence; note the following: –  Install poly V-belt → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. Tightening torques

Component	Nm
Tensioning roller to retaining plate	40
Toothed belt cover (centre) to cylinder block	10 1)
Toothed belt cover (top section) to cylinder head	10
Tensioner for poly V-belt to bracket for ancillaries	23
l  1) Install using locking fluid; for locking fluid refer to → Parts catalogue.