Removing and installing toothed belt assembly > 07.91: Audi (NG)

Special tools and workshop equipment required

Wrench for vibration damper 2079
Counterhold for vibration damper 2084
Counterhold 3036

Notes:

After detaching toothed belt, belt tension must be re-adjusted; for toothed belt drive ▸ 07.91 this is achieved by swivelling coolant pump.
To prevent leakage between coolant pump and cylinder block, coolant pump sealing ring must be replaced as described.

Removing

Engine in position

Drain coolant=> Page
19-4
.
Remove front bumper.

=> General Body Repairs, Exterior; Repair Group 63; Front Bumper; Removing and installing front bumper
General Body Repairs, Exterior
Front Bumper
Removing and installing front bumper

Remove upper radiator trim -arrows-.

Remove trim beneath headlights, lock carrier support and cross member at bottom with torque reaction support.

=> General Body Repairs, Exterior; Repair Group 50; Front Body
General Body Repairs, Exterior
Front Body

Note:

On vehicles with heavy-duty cooling, cross member can be removed complete with additional radiator.

Remove all V-belts => Page
13-1
onwards.
Set crankshaft at central bolt of crankshaft toothed belt sprocket in direction of engine rotation to no. 1 cyl. TDC mark ...
Vehicles with manual gearbox

Vehicles with automatic gearbox

Note:

Turning crankshaft to no. 1 cylinder TDC with engine removed

=> Page
13-59
.

... at the same time, mark -arrow- on rear of camshaft sprocket must coincide with top edge of gasket. If necessary, give crankshaft 1 further turn.

Remove upper and lower toothed belt guards -1- and -2-.
Mark direction of toothed belt with chalk or felt-tip pen.

Slacken off bolts -arrows- of coolant pump and swivel pump downwards.

Pull off rubber buffer at torque reaction support.

Remove vibration damper with crankshaft toothed belt sprocket; to do so, lock vibration damper with counterhold 2084.
Detach vibration damper and toothed belt.

Slacken off bolt of camshaft sprocket whilst providing support with 3036.
Pull off camshaft sprocket.
Remove Woodruff key from camshaft.

Unscrew rear toothed belt guard -bolts 1...3-.
Screw out remaining bolts for coolant pump and detach coolant pump.

Installing (adjusting valve timing)

Install in reverse order, paying attention to the following:

Notes:

When turning camshaft, none of the crankshaft cylinders should be at TDC, as this could result in valve/piston crown damage.
Toothed belt tension is to be adjusted when engine is cold.
Replace coolant pump O-ring.

Clean/smooth sealing surface for O-ring before fitting.
Moisten new O-ring with G11/G12 and apply at coolant pump.
Insert coolant pump and start by screwing it on loosely.
Fit rear toothed belt guard -bolts 1...3-.

Note:

Apply locking fluid "D 000 600 A2" when inserting bolts -3- at oil pump.

Fit Woodruff key.
Fit camshaft sprocket.

Fit bolt of camshaft sprocket (use counterhold 3036).

Align mark -arrow- at camshaft sprocket with top edge of gasket.

Check again to establish whether crankshaft is at no. 1 cylinder TDC.

Vehicles with manual gearbox

Vehicles with automatic gearbox

Note:

Turning crankshaft to no. 1 cylinder TDC with engine removed

=> Page
13-59
.

Position toothed belt on crankshaft toothed belt sprocket and fit with vibration damper/pulley at crankshaft.
Coat thread turns and resting surface of head of central bolt with sealing paste AMV 188 001 02.
Tighten central bolt slightly.

Position toothed belt on idler wheel, coolant pump and camshaft sprocket.
Tension toothed belt; to do so, rotate unfastened coolant pump upwards.

Check tension of toothed belt.
It must just be possible to turn toothed belt by 1/4 of a turn (90°) in centre between camshafts and idler shaft sprocket with thumb and index finger

Re-tension toothed belt if necessary.
Tighten coolant pump bolts.
Tightening torque for bolt with hexagon head: 20 Nm
Tightening torque for bolt with hexagon socket: 30 Nm

Give crankshaft two turns in direction of engine rotation and check whether camshaft and crankshaft marks coincide with their reference points.

Tighten central bolt for vibration damper (use counterhold 2084).
Tightening torque when using special tool 2079: 350 Nm

Attention:
Tightening torque of 350 Nm only applies in conjunction with special tool 2079. Tool must be aligned with torque wrench.

Tightening torque if use is not made of special tool 2079: 450 Nm

Fit upper and lower toothed belt guards -1- and -2-.
Fit V-belt =>Page
13-1
onwards.
Fit cross member at bottom with torque reaction support, lock carrier support and trim beneath headlights.

=> General Body Repairs, Exterior; Repair Group 50; Front Body
General Body Repairs, Exterior
Front Body

Install front bumper.

=> General Body Repairs, Exterior; Repair Group 63; Front Bumper; Exploded view of front bumper
General Body Repairs, Exterior
Front Bumper
Exploded view of front bumper

Fill with coolant=> Page
19-7
.
Check and if necessary adjust ignition point.

=> KE III Jetronic/Ignition System (5-cylinder); Repair Group 28; Checking ignition system; Adjusting ignition point
KE III Jetronic/Ignition System (5-cylinder)
Checking ignition system
Adjusting ignition point

Tightening torques

Component · Nm
Rear toothed belt guard · M6 · 10
M8 · 20
Camshaft sprocket to camshaft · 65
Coolant pump to cylinder block
Hexagon bolt · 20
Hexagon socket-head bolt · 30
Vibration damper with toothed belt sprocket to crankshaft
With special tool 2079 · 350
Without special tool 2079 · 450
Upper and lower toothed belt guard · 10