Removing and installing camshaft toothed belt — AUDI

Special tools and workshop equipment required

Pin wrench Matra V/159
V-belt and toothed belt test unit VW 210
Mandrel 2064
Setting bar 2065 A
Counterhold 3036
Support 3251

Removing

Remove the noise insulation -arrows-.
Remove the front bumper:

=> General Body Assembly; Repair group 63; Front bumper
General Body Assembly
Front bumper

Remove lock carrier:

=> General Body Assembly; Repair group 50; Front body
General Body Assembly
Front body

Unscrew bolt -2- of retaining clip of right headlight trim at housing.
Unscrew bolts -1- of air ducts on left and right of radiator and remove air ducts.
Loosen bolts -3- on left and right of radiator.

Detach cooling coil for power steering hydraulic fluid -arrows-.

Secure support 3251 on right bumper mounting and swing radiator forwards.
Remove ribbed belt => Page
13-8
.
Remove the viscous fan => Page
19-18
.
Remove cylinder head cover => Page
15-7
.
Remove the toothed belt guard for injection pump drive.
Remove the toothed belt guard for camshaft drive.

Note:

The engine can be turned using the hexagon attachment (32 mm A/F) located at the hydraulic pump.

Turn crankshaft to TDC of No. 1 cylinder -arrow-.
The -O- mark on the flywheel must be under the edge of the inspection hole ...

... at the same time, the marks on the injection pump sprocket and the injection pump must align -arrows-.

Notes:

If the marks do not align, give the crankshaft another turn.
Position crankshaft to TDC for cylinder 1 with engine removed=> Page
13-38
.

Lock injection pump sprocket using mandrel 2064.
Unscrew securing bolt of injection pump drive wheel at camshaft, using counterhold 3036 and ring spanner attachment V.A.G 1332/7.
Mark direction of rotation of toothed belt with chalk or felt pen.
Remove the drive wheel and toothed belt from the camshaft.

Lock the camshaft with setting bar 2065 A.
Release nut of toothed belt tensioning roller.
Remove the camshaft toothed belt from the camshaft sprocket.

Insert vibration damper counterhold 3248 as illustrated, and unscrew central bolt.
Unscrew the 4 securing bolts (M8) for vibration damper and remove vibration damper.
Remove the lower toothed belt guard.
Mark direction of rotation of toothed belt with chalk or felt pen.
Remove the camshaft toothed belt from the toothed belt sprocket (crankshaft).

Installing (adjusting valve timing)

Camshaft locked using setting bar.
Injection pump locked using mandrel 2064.

Notes:

The position of the toothed belt must be set as described below, even after repairs in which the belt is only taken off the camshaft sprocket.
When turning the camshaft, the crankshaft must not be at TDC at any cylinder. Danger of damage to valves/piston crown.
When loosening and tightening the camshaft sprocket, never use the setting bar to counterhold. Counterhold using 3036.

Loosen the securing bolt of the camshaft sprocket 1/2 turn. Release camshaft sprocket from camshaft taper by tapping (pin through hole on rear toothed belt guard) using hammer.
Tighten the camshaft sprocket until the sprocket can still just be turned, but does not tilt.

Install toothed belt guard - lower part.
Install the vibration damper=> Page
13-10
.

Turn eccentric of tensioning roller to right using pin wrench (e.g. Matra V/159).
Check toothed belt tension with VW 210.
Scale reading: 12...13

Note:

First completely release load on tensioning roller, if the eccentric cam was accidentally rotated too far clockwise while tensioning. Then again rotate the eccentric cam clockwise to tighten.

Tighten lock nut on tensioning roller to 45 Nm.
Tighten camshaft sprocket securing bolt initially to 50 Nm.

Note:

When loosening and tightening the camshaft sprocket, never use the setting bar to counterhold. Counterhold using 3036.

Turn camshaft until one end of setting bar 2065 A contacts the cylinder head.
Measure the clearance created at the opposite end using a feeler gauge.
Insert a feeler gauge corresponding to half the clearance between the setting bar and the cylinder head.
Turn camshaft until the setting bar lightly contacts the feeler gauge.
Insert a second feeler gauge corresponding to half the clearance between the setting bar and the cylinder head at the other end.

Loosen the securing bolt of the camshaft sprocket 1/2 turn. Release camshaft sprocket from camshaft taper by tapping (pin through hole on rear toothed belt guard) using hammer.
Tighten the camshaft sprocket until the sprocket can still just be turned, but does not tilt.

Note:

When loosening and tightening the camshaft sprocket, never use the setting bar to counterhold. Counterhold using 3036.

Turn crankshaft to TDC of No. 1 cylinder -arrow-.
Tighten the bolt of the camshaft sprocket as follows.
Bolt with strength rating 8.8: tighten to 85 Nm.
Replace bolt with bolt tightness 10.9 and tighten to 30 Nm + 90°

Note:

When loosening and tightening the camshaft sprocket, never use the setting bar to counterhold. Counterhold using 3036.

Check again whether TDC mark on flywheel and reference mark are aligned.
Remove setting bar.
Install injection pump drive wheel and toothed belt and check tension of toothed belt =>Page
13-33
.
Install cylinder head cover => Page
15-8
.
Install ribbed belt =>Page
13-9
.
Install viscous fan => Page
19-18
.

Installing lock carrier with attachments:

=> General Body Assembly; Repair group 50; Front body
General Body Assembly
Front body

Install the front bumper:

=> General Body Assembly; Repair group 63; Front bumper
General Body Assembly
Front bumper

Check commencement of injection of injection pump:

=> Diesel Injection and Glow Plug System (2.4 l engine); Repair group 23; Servicing diesel injection system
Diesel Injection and Glow Plug System (2.4 l engine)
Servicing diesel injection system

Tightening torques

Component · Nm
Toothed belt tensioning pulley · 45
Camshaft sprocket to · 8.8 · 85
Camshaft · 10.9 · 30 + 90°1)2)
Drive sprocket for injection pump to camshaft · 100
Power steering cooling coil to radiator · 10
Toothed belt guard · M6 · 10
M8 · 20

1)
Replace bolt

2)
90°corresponds to a quarter of a turn