Removing and installing toothed beltä 07.97: Audi 1.8 (ADR, AFY, APT, ARG, …)

AFY APT ARG AVV
Removing

Engine in vehicle
Lock carrier must be in service position => Page
13-1
.

Special tools, testers and auxiliary items

Pin wrench Matra V159

Remove ribbed belt and tensioning element for ribbed belt => Page
13-18
.
Remove viscous fan coupling (with belt pulley) => Fig.
13-17
.
Remove toothed belt guard (top).
Mark direction of rotation of belt with chalk or felt pen.
Set crankshaft to markings for TDC of No. 1 cylinder -arrows- by turning central bolt on crankshaft sprocket in direction of rotation.

Unbolt vibration damper.

Unbolt toothed belt guard (bottom section) -arrows-.

Loosen toothed belt tensioner with Torx wrench T45 -lower arrow-.
Press toothed belt tensioner downwards.
Take off toothed belt.

Installing (adjusting valve timing)

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.
The crankshaft must not be at TDC at any cylinder when the camshaft is turned. Otherwise there is a risk of damage to valves and piston crowns.
The setting can be performed with engine cold or engine warm.

Align marking on camshaft sprocket with marking on cylinder head cover.
Place toothed belt on crankshaft sprocket (observe direction of rotation).
Install toothed belt guard - lower part.
Secure vibration damper/belt pulley with one bolt (note fixing arrangement).
Turn crankshaft to TDC No. 1 cylinder.
Place toothed belt on tensioning roller and camshaft sprocket.

Tension toothed belt: to do this turn tensioner -A- with pin wrench -B- (e.g. Matra V159) to right until the piston -1- is fully extended and the tensioner piston -2- lifts approx. 1 mm.
Tighten securing bolt -3- hand-tight.
Turn crankshaft two full turns.

Check whether area -A- coincides with upper end of piston -2- (=> Fig. A13-0012); adjust if necessary.
Area -A-:
Setting OK
Area -B-:
Wear zone
Area -C-:
Make new adjustment, or check belt drive including tensioner for wear.

Note:

If the end of the piston is in area -A-, this corresponds to a distance -D- of 25 ... 29 mm.

Counter-hold toothed belt tensioner with pin wrench -B- and tighten securing bolt -3-.

Turn crankshaft two full turns in direction of rotation (by turning central bolt on crankshaft sprocket), and check that camshaft and crankshaft marks align with their reference points.
Install vibration damper/belt pulley.
Install toothed belt guard (top section).
Install ribbed belt and ribbed belt tensioning element=>Page
13-20
.

Tightening torques

Component · Nm
Toothed belt tensioner to tensioning roller · / 25
Toothed belt guard (bottom) to cylinder block · / M6 · / 10
M8 · 20
Vibration damper/belt pulley to crankshaft · / 40 1)
Ribbed belt tensioner to bracket · 25

1)
Bolt strength rating 10.9