TOOTHED DRIVE BELT, REMOVING, INSTALLING AND TENSIONING

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Owen Miller
5 years ago
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1 2005 Audi A4 Sedan (8E2) L4-1.8L Turbo (AMB) Vehicle > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Service and Repair > Removal and Replacement TOOTHED DRIVE BELT, REMOVING, INSTALLING AND TENSIONING Toothed drive belt, removing, installing and tensioning (Adjusting valve timing) 1/12

2 Special tools and equipment ^ V.A.G 1331 torque wrench (5 to 50 Nm) ^ Locking plate T10008 ^ V.A.G 1332 (40 to 200 Nm) torque wrench ^ Special tool 3387 Removing ^ With engine in vehicle. ^ Move upper radiator mount to service position, Refer to Body and Frame, Radiator Support, Service and Repair. ^ Remove engine cover by lifting up -arrows-. ^ Remove ribbed belt. ^ Remove ribbed belt tensioner -arrows-. 2/12

3 ^ Remove upper part of drive belt cover. Note: Take special note of the installed position of the upper part of the drive belt cover, particularly where it meets the center part of the drive belt cover. CAUTION: The engine must only be turned in the direction of engine rotation (clockwise) at the crankshaft. Note: To turn the engine over use the center bolt on the crankshaft. ^ Bring engine to TDC cylinder 1 by turning crankshaft in direction of engine rotation, using center camshaft drive 3/12

4 4/22/2018 Toothed Drive Belt, Removing, Installing and Tensioning (Timing Belt) - ALLDATA sprocket bolt on crankshaft. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1 -arrows-. ^ Unbolt vibration damper. ^ Remove center and lower part of drive belt cover. CAUTION: ^ The drive belt tensioner is oil-damped and can only be compressed slowly and with evenly applied force. ^ When compressing the tensioner, excessive force can damage the tensioning pulley. 4/12

5 ^ Push pulley on counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate T Note: The stop tab of the eccentric bolt must not be bent. ^ To release tension from drive belt, loosen nut -1- on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool ^ Mark direction of rotation of drive belt with chalk or felt tip pen. ^ Remove drive belt. Installing (adjusting valve timing) Note: ^ Even with repairs which require the drive belt to be removed only from the camshaft sprocket, the drive belt adjustment must be performed as follows. ^ When rotating the camshaft the crankshaft must not be at TDC for any cylinder. Risk of damaging valves/piston 5/12

crown. ^ Place drive belt on crankshaft sprocket (observe direction of rotation). ^ Install lower part of drive belt cover. Note: The vibration damper/pulley can be installed in only one position.

6 crown. ^ Place drive belt on crankshaft sprocket (observe direction of rotation). ^ Install lower part of drive belt cover. Note: The vibration damper/pulley can be installed in only one position. The hole -arrow- in the vibration damper must be located over the raised part on the crankshaft drive belt sprocket. ^ Tighten vibration damper/pulley, take note of locating point -arrow-. 6/12

7 ^ Align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-drive belt cover positioning marks. ^ Install drive belt in this order: water pump, tensioning pulley, camshaft sprocket. Tensioning drive belt If the drive belt tensioner is completely extended CAUTION: ^ If the drive belt tensioner is at its travel limit, it must be pushed back in the installed position together with the pulley This procedure can take up to 5 minutes. ^ When compressing the tensioner, excessive force can damage the tensioning pulley. 7/12

8 ^ Push pulley on counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate T All Note: The stop tab of the eccentric bolt must not be bent. ^ Turn eccentric bolt counter-clockwise in direction of arrow using special tool ^ Hold eccentric bolt in this position and withdraw locking plate T /12

9 ^ Turn eccentric bolt clockwise to right in direction of arrow until a gauge -2- with dimension -a- (e.g. drill bit) can be passed between tensioning lever and tensioner housing. ^ Dimension a = 8 mm ^ Hold eccentric bolt in this position and tighten pulley nut -1-. Tightening torque: 27 Nm CAUTION: The engine must only be turned in the direction of engine rotation (clockwise) at the crankshaft. Note: To turn the engine over apply tool at the center bolt on the crankshaft. ^ Turn crankshaft two complete turns in direction of engine rotation until crankshaft is at TDC again. 9/12

10 Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1 -arrows-. ^ Check dimension -a- between tensioning lever and tensioner housing with a gauge -2- (e.g. drill bit). ^ Dimension a = 6-10 mm If dimension -a- is not obtained 10/12

11 CAUTION: ^ The drive belt tensioner is oil-damped and can only be compressed slowly and with evenly applied force. ^ When compressing the tensioner, excessive force can damage the tensioning pulley. ^ Push pulley on counter-clockwise in direction of arrow with a socket head wrench using even but not excessive application of force until tensioner piston can be locked with locking plate T ^ Loosen nut -1- on pulley. ^ Continue under"tensioning drive belt, Refer to Toothed Drive Belt, Removing, Installing and Tensioning. If dimension -a- is obtained ^ Install center and upper drive belt cover. 11/12

12 ^ Install ribbed belt tensioner. ^ Install ribbed belt. Tightening Torques 1) Install using locking adhesive- Parts Supplier 2) Replace bolts 3) 90 equals one quarter turn 12/12

Engine, disassembly and

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