Audi Workshop Service and Repair Manuals

Removing and installing toothed belt

Special tools and workshop equipment required

t	Pin wrench -3212-

t	Pin wrench -3387-

t	Locking pin -T40011-

t	Locking pin -T40026-

t	Socket -T40028-

t	Camshaft clamp -T40030-

t  Puller -T40039-

Removing –  Move lock carrier to service position → Chapter. –  Remove tensioner for poly V-belt → Chapter. –  Unbolt power steering pump pulley -arrows- (counterhold with pin wrench -3387-).

–  Unscrew the 8 bolts -1-. –  Remove vibration damper -2- and thrust washer -3-, if fitted.   Note The thrust washer -3- is only fitted in conjunction with toothed belt sprocket -06C 105 063 A-. If toothed belt sprocket -06C 105 063 B- is fitted, do NOT install thrust washer.

–  Remove bolts -1 ... 12- and take off toothed belt cover (front left, front right and bottom).

–  Pull off engine cover panel (rear) -arrows-.

–  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at expansion tank (bottom) and move expansion tank to one side (coolant hoses -1 ... 3- remain attached).

–  Remove air cleaner housing -arrows-. –  Unplug electrical connector -1- at air mass meter -G70-. –  Remove air intake hose -2- with air mass meter -G70-.

–  Remove bolts -1- and -3-. –  Disconnect hose -4- at pipe for secondary air. –  Pull guide tube -2- for oil dipstick upwards out of top section of sump and fold forwards.

–  Unscrew bolts -5- and -6- on cylinder head cover (right-side). –  Unplug electrical connectors -1 ... 4-. –  Pull out ignition coils -arrows- using puller -T40039-.

–  Detach crankcase breather hose -arrow-. –  Unscrew cylinder head cover bolts (right-side) in the sequence -12 ... 1-. –  Remove cylinder head cover.

–  Unscrew bolts -4- and -5- on cylinder head cover (left-side). –  Unplug electrical connectors -1 ... 3- and -6-. –  Pull out ignition coils -arrows- using puller -T40039-.

–  Detach crankcase breather hose -arrow-. –  Unscrew cylinder head cover bolts (left-side) in the sequence -12 ... 1-. –  Remove cylinder head cover.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Turn engine until cams -arrows- of intake and exhaust camshafts at cylinder No. 3 (right-side cylinder bank) point upwards at equal angles.   Note Turn over the engine at the central bolt on the crankshaft.

–  Attach camshaft clamp -T40030- to camshafts on cylinder head (right-side).   Note Turn the crankshaft slightly backwards and forwards so that the claws of camshaft clamp -T40030- can engage properly in the camshafts. –  Expand camshaft clamp -T40030- by means of the threaded spindle (tightening torque max. 10 Nm) until it is seated with zero play.

–  Attach camshaft clamp -T40030- on cylinder head (left-side) in the same way.

–  If fitted, unplug electrical connector at continued circulation coolant pump -V51-. –  Unscrew plug for TDC marking from cylinder block. –  Screw locking pin -T40026- into bore; if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.   Note

Catch escaping oil with a cloth. –  Pry off circlips -1- for sealing caps -2- on all camshaft sprockets using a screwdriver -3-.

–  Loosen securing bolts -1 ... 4- for camshaft sprockets.   Note Leave bolts screwed in loosely.

–  Use an 8 mm hexagon key to turn toothed belt tensioning roller in direction of -arrow- until tensioning lever has compressed tensioner far enough to allow locking pin -T40011- to be inserted in holes in piston and housing.   Note t  The toothed belt tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure. t  Before removing, mark rotation direction of toothed belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

–  Loosen bolt -arrow- for eccentric adjuster. –  Remove toothed belt. Installing (adjusting valve timing) l  Camshafts locked in position with camshaft clamp -T40030-. l  Crankshaft locked in position with locking pin -T40026-. l  Camshaft sprockets free to turn.   Note t  Renew gaskets, seals, O-rings and self-locking bolts. 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.

–  Tighten the camshaft sprocket bolts until the sprockets -1 ... 4- can still just be turned, but do not move axially. –  Fit toothed belt as illustrated. l  To ensure accurate valve timing adjustment, the toothed belt must be exactly in line with the front edge of all belt sprockets.

–  Using pin wrench -3387-, turn the eccentric adjuster -1- clockwise until the handle of the pin wrench is exactly over the centre axis of coolant pump pulley -2-. –  Hold pin wrench -3387- in this position and tighten bolt -3- to 45 Nm.

–  Apply torque wrench horizontally to hexagon socket of tensioner lever. –  Pre-tension toothed belt by applying a torque of 45 Nm in the direction indicated by the -arrow-.

–  Turn toothed belt tensioning roller in direction of the -arrow- using an 8 mm hexagon key until the locking pin -T40011- can be removed.

–  Apply torque wrench horizontally to hexagon socket of tensioner lever. –  Tension toothed belt by applying a torque of 25 Nm in the direction indicated by the -arrow-.

–  Apply socket -T40028- to camshaft adjuster for exhaust camshaft on cylinder bank (left-side). –  Turn rotor of camshaft adjuster clockwise as far as it will go -arrow- with a torque of 10 Nm.

–  Turn rotor of camshaft adjuster on cylinder bank (right-side) clockwise as far as it will go -arrow- with a torque of 10 Nm. –  Tighten camshaft sprockets to 100 Nm.

–  Install caps -2- with new O-rings -1- on camshaft sprockets and secure with circlips.   Note Disregard -item 3-. –  Remove camshaft clamp -T40030-. –  Remove locking pin -T10026- and screw plug for TDC marking into cylinder block together with new O-ring. Remaining installation steps are carried out in reverse sequence; note the following: –  Install cylinder head covers: left-side → Chapter, right-side → Chapter. –  Install toothed belt covers → Chapter. –  Install vibration damper → Chapter. –  Install tensioner for poly V-belt → Chapter. –  Install poly V-belt → Chapter. –  Install lock carrier with attachments → Rep. Gr.50. –  Install bumper cover (front) → Rep. Gr.63. Tightening torques

Component	Nm
Eccentric adjuster to front sealing flange	45
Camshaft sprocket to camshaft	100
Sealing plug in cylinder block	25
Pulley to power steering pump	23