Removing, replacing and installing toothed belt: Audi 1.8 (AGN, APG)

APG
Special tools and workshop equipment required

Engine support bracket 10-222 A
Retainer T10013
Tensioning bolt T10092
Locking pin T40011

Removing

Remove ribbed belt => Page
13-9.
Remove tensioning element for ribbed belt -arrows-.

Disconnect the coolant expansion tank -1-, the power steering fluid reservoir -2- and the ACF filter -3-. The hoses remain connected.

Turn crankshaft to TDC position of No. 1 cylinder with engine installed => Page
13-37.
Turn crankshaft to TDC position of No. 1 cylinder with engine removed => Page
13-42.
Unbolt vibration damper.

Note:

When loosening and tightening the bolts securing the vibration damper, counter-hold central bolt with a ring spanner.

Unbolt bottom and centre sections of toothed belt guard -arrows-.

Insert the retainer T10013 in the lifting eye (right side) and lock into place by positioning the washer off centre.

Note:

Insert suitable plastic or wooden packing between the bolted wing flange and the side panel to prevent deformation of the wing panel.

Set up engine support bracket 10-222 A in front of gas strut on bolted flanges of wing panels with spindles at front.
Engage hooks at spindle ends in the retainer T10013.

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

Unbolt connecting piece between engine console and body -arrows-.
Unbolt engine console from engine support and from body -arrows-.
Take out engine console.

Unscrew the engine support bolts -1 ... 3- and swing engine support to the rear slightly.

Note:

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

Screw tensioning bolt T10092 into tensioning element for toothed belt.
Only compress the piston of the tensioning element as far as is necessary to insert locking pin T40011.

Note:

The locking pin T40011 will be easier to insert if it is turned about 90° first.

Mark direction of rotation of belt with chalk or felt pen.
Pull out toothed belt through space between engine support and cylinder block.

Installing (adjusting valve timing)

Note:

When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.

Align marking on camshaft sprocket with marking on cylinder head cover -arrows-.

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

Vehicles with automatic gearbox

Note:

Turning crankshaft to TDC No. 1 cylinder with engine removed

=> Page
13-42.

Place toothed belt on crankshaft sprocket (observe DOR).
Fit toothed belt onto coolant pump, then tensioning roller, and finally camshaft sprocket.
Unscrew tensioning bolt T10092.
Pull locking pin T40011 out of tensioning element.
piston of toothed belt tensioning element relaxes

Turn crankshaft two full turns in direction of rotation (by turning central bolt on crankshaft sprocket). Check that marks on the camshaft and the crankshaft align with their respective reference points.
Install toothed belt guard.

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

Tighten the engine support as follows:

Tighten bolts -1 ... 3- hand tight.
Then tighten the bolts -1 ... 3- to 45 Nm.
Install the engine console.
Install vibration damper
=> Page
13-7.
Readjust engine mountings => Page
10-46.
Install ribbed belt =>Page
13-10.
Install and secure coolant expansion tank, power steering fluid reservoir and ACF filter.

Tightening torques

Component · Nm
Bottom section of toothed belt guard to cylinder block · / 10 1)
Centre section of toothed belt guard to cylinder block · / 10 1)
Engine support to cylinder block · 45
Engine console to body · 40 + 90°2)3)
Connecting piece to body/ engine console · / 25
Ribbed belt tensioner to bracket for auxiliary units · 25

1)
Insert with thread-locking adhesive; thread-locker

=> Parts catalogue

2)
Renew bolts

3)
90° is a quarter turn