Audi Workshop Service and Repair Manuals

Removing and installing toothed belt for high-pressure pump Special tools and workshop equipment required

t  Counterhold tool -3036-

t  Locking pin -3242-

t  Puller -T10320-

t  Adapter -T40058-

t  Locking tool -T40135- for adjusting high-pressure pump Removing –  Remove top section of intake manifold → Chapter.

–  Pivot toothed belt cover forwards -arrows- and disengage retaining pegs on bottom side of toothed belt cover.   Note For illustration purposes, the toothed belt cover is shown with the top section of the intake manifold removed.   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 turn.

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

–  Remove toothed belt drive sprocket using puller -T10320-.   Note Leave toothed belt drive sprocket on camshaft. –  First detach toothed belt from toothed belt sprocket for high-pressure pump and then from toothed belt drive sprocket. Installing Installation is carried out in the reverse order; note the following:

–  Release fasteners -1 ... 4- and remove noise insulation panels.

–  Insert guide pin of adapter -T40058- as follows: l  The larger-diameter section -arrow 1- faces towards the engine. l  The smaller-diameter section -arrow 2- faces the adapter.

Caution Irreparable damage can be caused if the camshaft timing chain slips. Turn crankshaft only in direction of engine rotation -arrow-. –  Use adapter -T40058- to turn crankshaft to „TDC“ position.

l  Mark -arrow- must be perpendicular to centre of crankshaft, as shown in illustration. –  Remove air intake hoses.

–  Remove sealing plug -arrow- at rear of cylinder head (right-side).   Note For illustration purposes, the installation position is shown from rear and with engine removed. –  Check whether groove -arrow- in camshaft flange can be seen through bore -1- for sealing plug.

–  To do so, shine a small torch into bore for sealing plug.   Note For illustration purposes, camshaft flange is shown without chain drive and timing chain cover. –  If groove is not positioned under bore, turn crankshaft 360  further in direction of engine rotation.   Note

Place a cloth underneath sump (top section) to catch any escaping engine oil. –  Unscrew plug -arrow- from sump (top section).

WARNING Risk of injury while feeling for the „TDC“ hole with your finger. Do NOT turn crankshaft -1-. –  Screw locking pin -3242- into hole (20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.   Note Before installing toothed belt make sure high-pressure pump and toothed belt sprocket for high-pressure pump are firmly in position.

–  Lock toothed belt sprocket for high-pressure pump in position using locking tool -T40135-.   Note t  Before fitting tooth belt, toothed belt sprocket for high-pressure pump must be locked in position using locking tool -T40135-. This is important to prevent oscillation of toothed belt.

t  The hole -arrow on toothed belt sprocket- is located at "3 o'clock" position.

t  Locking tool -T40135- must be inserted all the way.

–  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.

–  Screw in bolt -1- 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 -2- 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 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 toothed belt 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.

–  Remove locking pin -3242-.

–  Screw plug -arrow- for „TDC“ marking into sump (top section) → Rep. gr.17.

–  Insert guide pin of adapter -T40058- as follows: l  The larger-diameter section -arrow 1- faces towards the engine. l  The smaller-diameter section -arrow 2- faces the adapter.

Caution t  Irreparable damage can be caused if the camshaft timing chains slip. t  Turn crankshaft only in direction of engine rotation -arrow-. –  Turn crankshaft 1 rotation using adapter -T40058-.

–  Check toothed belt tension: l  Lug -1- should align with notch -2-. –  If the specification is not attained, re-adjust toothed belt tension. The remaining installation steps are carried out in the reverse sequence. –  Install top section of intake manifold → Chapter.