Toothed belt, removing and installing: Installing

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2004 Audi A6, 2003 Audi S6, 2003 Audi A6, 2002 Audi S6, and 2002 Audi A6. However, it is still accessible from the selected car via links, so may be relevant.

First install toothed belt on crankshaft sprocket, idler wheel for tensioner, tensioning roller, camshaft sprocket for cylinder bank 5-8, coolant pump and damper wheel.
Then take camshaft sprocket for cylinder bank 1-4, install toothed belt and bolt sprocket onto camshaft.
Lightly secure both camshaft sprockets with securing plates by tightening hand-tight.

Fig 1: Installing Toothed (Timing) Belt On Crankshaft Sprocket, Idler Wheel For Tensioner, Tensioning Roller
Courtesy of AUDI OF AMERICA, INC.

NOTE: The camshaft sprockets must be tight enough on the camshaft tapers to be turned but not to be moveable axially.
Attach camshaft bar T40005.
Insert a 5 mm drill bit between tensioner and hydraulic piston -arrow-.

Fig 2: Inserting 5 mm Drill Bit Between Toothed (Timing) Belt Tensioner And Hydraulic Piston

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Courtesy of AUDI OF AMERICA, INC.

Tension toothed belt initially to 4 Nm (35 in. lb) using tensioning key T40009 and torque wrench VAG 1410 with socket attachment VAS 5122 by turning in direction of arrow. Then tighten eccentric wheel to 22 Nm (16 ft lb).
Remove 5 mm drill bit.

Fig 3: Tensioning Toothed Belt Using Tensioning Key T40009 And Torque Wrench VAG 1410 With Socket Attachment VAS 5122

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Courtesy of AUDI OF AMERICA, INC.

Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until T40011 can be removed.

Fig 4: Using 8 mm Allen Key To Turn Toothed Belt Tensioning Lever

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Courtesy of AUDI OF AMERICA, INC.

Using 8 mm Allen key, turn toothed belt tensioning lever in direction of arrow until 7 mm drill bit can be inserted between toothed belt tensioning lever and hydraulic tensioning element.
Tighten bolts on camshaft sprockets.
NOTE: Use camshaft bar T40005 to prevent camshafts from turning.
Remove camshaft bar T40005.
Remove 7 mm drill bit.

Fig 5: Removing 7 mm Drill Bit From Toothed Belt Tensioner
Courtesy of AUDI OF AMERICA, INC.
Remove crankshaft clamping bolt 3242 and install sealing plug in hole.
Turn crankshaft 2 revolutions.
Measure dimension -a- between toothed belt tensioning lever and hydraulic tensioning element.
- Dimension a = 5 mm.
If distance is not correct, re-adjust tensioning roller to 5 mm.

Fig 6: Measuring Dimension -A- Between Toothed Belt Tensioning Lever And Hydraulic Tensioning Element

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Courtesy of AUDI OF AMERICA, INC.

Check dimension -a- of belt guard with feeler gauge.
- Dimension -a- = 1 mm (0.0393 in.)
Right cover, adjusting
Turn crankshaft until all bolts -arrows- are exposed.
Loosen all bolts -arrows- of cover.

Fig 7: Locating All Right Cover Bolts
Courtesy of AUDI OF AMERICA, INC.
Adjust dimension -a- using feeler gauge to 1mm (0.0393 in.).
Check dimension -a- of belt guard with feeler gauge.
- Dimension -a- = 1 mm (0.0393 in.)
Left cover, adjusting
Turn crankshaft until all bolts -arrows- are exposed.
Loosen all bolts -arrows- of cover.
Adjust dimension -a- using feeler gauge to 1 mm (0.0393 in.).

Fig 8: Locating All Left Cover Bolts And Checking Dimension -A- Of Belt Guard

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Courtesy of AUDI OF AMERICA, INC.

TIGHTENING TORQUES: TOOTHED (TIMING) BELT

Tightening torques

Toothed belt sprocket to camshaft

55 Nm (41 ft lb)

Idler wheel

45 Nm (33 ft lb)

Toothed belt tensioning roller

20 Nm (15 ft lb)

Pulley to crankshaft

20 Nm (15 ft lb)

Toothed belt tensioner

10 Nm (7 ft lb)

Eccentric wheel

22 Nm (16 ft lb)

Center bolt to crankshaft ⁽¹⁾)

200 Nm + 180° (148 ft lb 180° ⁽²⁾

Cover to cylinder head

10 Nm (7 ft lb)

⁽¹⁾	Always replace center bolt.

⁽²⁾	Turning in two stages of 90° is also permissible.