Removing and installing complete toothed belt: Audi 1.6 (AEH, AKL, APF)

AKL APF
Special tools and workshop equipment required

Support bar 10-222A

Pin wrench T10020

Removing

Remove engine covers -arrows-.

Note:

Illustration shows bolted engine cover.

Remove ribbed belt => Page
13-9
.
Remove tensioner for ribbed belt cover -arrows-.

Detach the coolant expansion tank -1-, refill reservoir -2- for power steering and ACF -3-. Do not detach hoses.

Position crankshaft to TDC for cylinder 1 with engine installed => Page
13-39
.
Position crankshaft to TDC for cylinder 1 with engine removed => Page
13-43
.
Remove the crankshaft pulley.

Note:

To loosen and tighten the crankshaft pulley, counterhold with a ring spanner at the central bolt.

Unbolt lower and centre toothed belt guards -arrows-.

Note:

Push a plastic or wooden support between the wing mounting flange and side panel in order to prevent deformation of the wing.

Set up support bar 10-222 A on wing panel flanges. Spindle is at front.
Attach the snap hook of the spindle to the right lifting eye.

Lift engine slightly with spindle of engine support bracket 10 222 A.

Unbolt brace between engine console and chassis -arrows-.
Unbolt engine console from engine support and from chassis -arrows-.
Take out engine console.

Remove bolts for engine support -1...3- and swivel engine support slightly to the rear.

Note:

To remove the bolts for the engine support, raise or lower the engine slightly as necessary using the spindles on engine support bracket 10-222A.

Mark running direction of belt with chalk or felt pen.
Loosen the tensioning roller nut -arrow- by several turns.
Remove toothed belt.

Installing (adjusting valve timing)

Notes:

Adjustments to the toothed belt may only be performed when engine is cold.
When turning the camshaft, the crankshaft must not be at TDC for any piston. Danger of damage to valves/piston crown.

Bring mark on camshaft sprocket in line with the mark on toothed belt guard -arrows-.

Check again whether the crankshaft is positioned to TDC for cylinder 1:
Vehicles with manual gearbox

Vehicles with automatic gearbox

Note:

Position crankshaft to TDC for cylinder 1 with engine removed=> Page
13-43
.

Place toothed belt on crankshaft sprocket (observe DOR).
Fit toothed belt onto coolant pump, then tensioning roller, and finally camshaft sprocket.

Note installation position of semi-automatic tensioning roller:
Retaining lug -arrow- must engage in slot on cylinder head.

Before tensioning the toothed belt, turn the tensioning roller at the eccentric cam using pin wrench T10020 five times to the stop in both directions.
Tension the toothed belt. Turn pin wrench T 10020 to the stop in direction of arrow at the eccentric cam for this purpose.
Then relieve the toothed belt tension until the notch -1- and the pointer -2- are aligned (use a mirror).
Tighten securing nut to 20 Nm.

Crank crankshaft at central bolt of the toothed belt crankshaft in direction of engine rotation twice and check whether the camshaft and crankshaft markings align with their respective reference points.
Install toothed belt guard.

The remaining installation steps are performed in the reverse sequence - note the following points:

Secure the engine support as follows:

Remove bolts -1...3-.
Then tighten the bolts -1...3- to 45 Nm.
Install engine console.
Install the crankshaft pulley => Page
13-7
.
Adjust engine mounting => Page
10-66
.
Install ribbed belt=> Page
13-11
.
Install coolant compensation tank, refill reservoir for power steering and ACF.

Tightening torques

Component · Nm
Tensioning roller to cylinder head · 20
Lower toothed belt guard to cylinder block · 10 1)
Centre toothed belt guard to cylinder block · 10 1)
Engine support to cylinder block · 45
Engine console to chassis · 40 + 90°2)3)
Brace to body/engine console · 25
Tensioner for ribbed belt tensioner to bracket for auxiliary mechanical units · 23

1)
Install using locking compound;
locking compound

=> Parts List

2)
Replace bolts

3)
90°corresponds to a quarter of a turn