Audi Workshop Service and Repair Manuals

Removing and installing toothed belt Special tools and workshop equipment required

t  Pin wrench -T10020-

t  Locking pin -T40098- Removing

–  Pull off engine cover panel -arrows-.   WARNING Hot steam/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open filler cap on coolant expansion tank

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-release fasteners -1- and -2- and take off front noise insulation. –  Drain off coolant → Chapter. –  Move lock carrier to service position → Chapter.

–  Disconnect coolant pipe -arrow-.   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. –  Mark direction of rotation of poly V-belt.

–  To slacken poly V-belt, turn belt tensioner/damper in direction of -arrow-. –  Lock tensioner in position with locking pin -T40098-. –  Remove poly V-belt.

–  Set camshaft sprocket to TDC marking by turning crankshaft. Marking on camshaft sprocket must align with arrow on toothed belt cover.

–  Remove vibration damper / pulley.

–  Unscrew bolts from toothed belt cover (bottom) -arrows-.

–  Unscrew remaining toothed belt cover bolts -arrows- and remove toothed belt cover from engine. –  Mark direction of rotation of toothed belt. –  Loosen tensioning roller and remove toothed belt. –  Turn crankshaft back slightly. Installing l  Tightening torques → Chapter „Toothed belt drive - exploded view“   Note t  When turning the camshaft, the crankshaft must not be at TDC. Otherwise, there is a risk of damage to valves and piston crowns. t  The engine must be no more than warm to touch. –  Fit toothed belt on crankshaft sprocket (note rotation direction). –  Secure toothed belt cover (bottom section) with the two bolts at the bottom. –  Install vibration damper / pulley with new bolts.

–  Turn crankshaft and camshaft to TDC No. 1 cylinder -arrows-.

–  Fit toothed belt in the sequence: tensioning roller, camshaft sprocket, coolant pump and last onto idler roller -arrow-.   Note

Check tensioning roller is seated correctly in cylinder head.

–  Tension toothed belt. To do so, turn hexagon key at the eccentric adjuster clockwise (direction of arrow) until the notch is above the indicator. –  Then release tension on toothed belt. –  Now tension toothed belt until the notch and the indicator are aligned. –  Tighten securing nut for tensioning roller. –  Turn crankshaft two turns in direction of engine rotation and set again to TDC. Make sure that the engine is rotated without stopping during the final 45° (1/8 turn). –  Check tension of toothed belt again. Specification: indicator and notch must align.

–  Check valve timing again. If the markings do not align: –  Repeat adjustment of valve timing. If the markings align:

–  Install toothed belt cover -arrows-. –  Install crankshaft pulley → Chapter. –  Install poly V-belt → Chapter. –  Fill up with coolant → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; 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-. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Check headlight adjustment → Booklet803. –  Install insulation tray. –  Fit engine cover panel.