Audi Workshop Service and Repair Manuals

Removing and installing toothed belt for high-pressure pump - vehicles up to 02.2006

Special tools and workshop equipment required

t	Puller -3032-

t	Counterhold tool -3036-

t	Adapter -T40058-

Removing –  Remove engine cover panel → Chapter. –  Remove intake manifold (top section) → Chapter. –  Loosen clamps -arrows-. –  Pivot toothed belt cover forward and disengage retaining pegs on bottom side of toothed belt cover.   Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of toothed belt with chalk or felt-tip pen for re-installation.

–  Loosen bolt -arrow- for toothed belt tensioning roller approx. 2 turns.

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

–  Open quick-release fasteners -1 … 3- and take off front and rear noise insulation.

–  Unplug electrical connector -1-. –  Move wiring harness clear at radiator fan (left-side). –  Remove bolts -arrows-. –  Lower radiator fan (left-side) slightly and tie up on lock carrier.

–  Loosen central bolt -1- for toothed belt drive sprocket approx. 2 turns using counterhold tool -3036-.

–  Use puller -3032- to pull off toothed belt drive sprocket. –  Take off toothed belt drive sprocket together with toothed belt. Installing Installation is carried out in the reverse order; note the following:

–  Check installation position of toothed belt tensioning roller: l  Retaining lug -arrow 2- must engage in slot on bracket for high-pressure pump. l  Tensioning roller must be slack and hexagon socket -arrow 1- must face downwards. –  Fit toothed belt together with toothed belt drive sprocket. –  Install toothed belt tensioning roller; to do so, screw in bolt for toothed belt tensioning roller without applying force until eccentric adjuster of toothed belt tensioning roller can just still be turned without axial movement. –  Screw in bolt for toothed belt drive sprocket until toothed belt drive sprocket can just still be turned without axial movement.

–  Tension toothed belt tensioning roller slightly by turning further in direction of -arrow- using hexagon key until hexagon socket is in "1 o'clock" position.   Caution Do NOT turn tensioning roller up to or beyond „12 o'clock“ position.

–  Now release toothed belt tensioning roller -arrow- to such an extent that hexagon socket moves into "3 o'clock" position.

–  Tension tensioning roller slightly from "3 o'clock" position -arrow- until lug -1- and notch -2- are exactly in line.

–  Hold toothed belt tensioning roller in this position and tighten bolt -arrow- → Item.

–  Tighten bolt -1- for toothed belt drive sprocket using counterhold tool -3036- → Item.

Turn crankshaft one complete revolution to check toothed belt tension. To do this: –  Insert guide pin of adapter -T40058- with the larger-diameter section -arrow 1- facing towards the engine. The smaller-diameter section -arrow 2- faces the adapter.

–  Turn crankshaft at least one complete revolution in normal running direction -arrow-.

–  Check toothed belt tension. l  Lug -1- should align with notch -2-. If specification is not obtained: –  Adjust the toothed belt tension again. Installation is carried out in the reverse order; note the following: –  Install radiator fan → Rep. gr.19. –  Install intake manifold (top section) → Chapter. Tightening torques

Component	Nm
Toothed belt drive sprocket to camshaft	75
Toothed belt tensioning roller to front bracket	23