Removing and installing toothed belt > approx. 05.99 — AUDI

AJL ANB APU
Special tools and workshop equipment required

Pin wrench Matra V159

Removing

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

Remove engine cover -arrows-.
Remove ribbed belt and tensioner for ribbed belt => Page
13-22
.

Secure pulley for viscous fan with a bolt M5 x 60 mm.
Remove pulley and viscous fan using an 8 mm Allen key.
Remove viscous fan from mounting.
Remove upper toothed belt guard.

Mark direction of rotation of belt with chalk or felt pen.

Position crankshaft on central bolt of toothed belt crankshaft into engine rotation direction to marking TDC cyl 1 -arrows-.

Unbolt vibration damper.

Unbolt toothed bottom belt guard -arrows-.

Loosen toothed belt system with TORX key T45 -arrow below-.
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.
When turning the camshaft, the crankshaft must not be at TDC at any cylinder. Danger of damage valves/piston crown.

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

Tension toothed belt. For this turn tensioner -A- clockwise with 2-pin hole wrench -B- (e.g. Matra V159) clockwise until the piston -1- is extended completely and the piston of the tensioner -2- raises itself by approx. 1 mm.
Tighten securing bolt -3- hand-tight.
Turn crankshaft two full turns.

Check whether area -A- aligns with top edge of piston -2- (=> Fig. A13-0012) and adjust, if necessary.
Area -A-:
Adjustment OK
Area -B-:
Wear range
Area -C-:
Check readjustment or belt drive inclusive of tensioning roller for wear

Note:

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

Counterhold toothed belt system with 2-hole pin wrench -B- and tighten securing bolt -3-.

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 vibration damper/belt pulley.
Install toothed belt guard (top section).
Install viscous fan => Page
13-28
.
Install ribbed belt and tensioner for ribbed belt => Page
13-24
.
Install lock carrier =>Page
13-1
.

Tightening torques

Component · Nm
Toothed belt tensioner to tensioning roller · / 25
Toothed belt guard on bottom of / cylinder block · / / M6 · / / 10
M8 · 20
Vibration damper/belt pulley to crankshaft · /
Bolt strength rating · 8.8 · 10 + 90°1)2)
Bolt strength rating · 10.9 · 40
Ribbed belt tensioner to retainer · / 25

1)
Renew bolts

2)
90°corresponds to a quarter turn