Removing and installing injection pump toothed belt — AUDI

ABP AEL
Special tools and workshop equipment required

Tensioner 3303

Removing

Audi A6:

Remove engine cover -arrows-.

All models:

Remove the toothed belt guard for injection pump drive.

Note:

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

Turn the crankshaft to cylinder 1 TDC -arrow-.
The -O- mark on the flywheel must be located 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
13-45
.

Loosen the tensioning roller nut -arrow- by approx. 1 turn.
Mark direction of rotation of toothed belt with chalk or felt pen.
Remove toothed belt.

Installing

Crankshaft in TDC-position for cylinder 1 => Page
13-39

Installation is carried out in the reverse order; note the following:

Notes:

Ensure that before positioning the toothed belt, the eccentric of the tensioning roller is turned so that the tensioning lever, with the spring of tensioner 3303 attached, presses on the roller against the toothed belt.
The spring of the tensioner 3303, when the tensioning roller is released, automatically sets the belt to the correct tension.

Check whether the marks on the injection pump sprocket and the injection pump are aligned -arrows-.

Audi A6:

Unscrew nut -A- on rear toothed belt guard for injection pump drive.
Push toothed belt guard and sleeve -B- to rear.

Note:

In order to attach the tensioner for the Audi A6 without removing the stud, first file out a section of the tensioner, as shown in the illustration (shaded area).

All models:

Loosen the tensioning roller nut -arrow- by approx. 1 turn.
Move the tensioning roller by hand to check that it moves easily; free the roller if necessary.
Fit toothed belt (observe direction of rotation).
Hook in spring of tensioner 3303.
Turned the crankshaft approx. 1/2 turn in running direction.
Tighten nut -arrow- on tensioning roller.
Remove tensioner 3303.
Check commencement of injection of injection pump:

=> Diesel Direct Injection and Glow Plug System (TDI 5-cylinder); Repair group 23; Servicing diesel direct injection system
Diesel Direct Injection and Glow Plug System (TDI 5-cylinder)
Servicing diesel direct injection system

Install toothed belt guard.

Tightening torques

Component · Nm
Nut for tensioning roller · 45
Toothed belt guard · M6 · 10
M8 · 20