Toothed belt, removing from camshaft sprockets: Installing

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Place toothed belt over camshaft sprocket for cylinder bank 1-4 and install sprocket on camshaft.
Hand-tighten both camshaft sprockets with securing plates.
NOTE: The camshaft sprockets must be tight enough on the camshaft tapers to be turned but not moveable axially.
Attach camshaft bar T40005.
Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until pin T40011 can be removed.
NOTE: Camshaft clamp T40005 is used to prevent camshafts from turning.

Fig 1: Using 8 mm Allen Key To Turn Toothed Belt Tensioning Lever

G02724644

Courtesy of AUDI OF AMERICA, INC.

Remove camshaft bar T40005.
Remove crankshaft clamping bolt 3242 and install sealing plug.
Turn crankshaft by 2 revolutions.
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.
Adjust dimension -a- using feeler gauge to 1 mm (0.0393 in.).

Fig 2: Locating Right Cover And Checking Dimension -A- Of Belt Guard

G02724645

Courtesy of AUDI OF AMERICA, INC.

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 3: Locating All Left Cover Bolts And Identifying Dimension -a-

G02724646

Courtesy of AUDI OF AMERICA, INC.

NOTE: When installing a used ribbed belt, be sure that the belt runs in the correct direction and seats properly on the belt pulleys.

Install ribbed belt on crankshaft pulley and idler wheels first. Install belt on tensioning roller last.

Fig 4: Ribbed (Serpentine) Belt Routing

G02724647

Courtesy of AUDI OF AMERICA, INC.

To tension ribbed belt, turn tensioner clockwise (arrow) with 19 mm ring wrench and remove pin 3204.
Start engine and check that belt runs correctly.

Fig 5: Removing Pin 3204 From Ribbed (Serpentine) Belt Tensioner

G02724648

Courtesy of AUDI OF AMERICA, INC.

Install viscous fan with outer ring (FAN HAS LEFT-HAND THREAD).

Fig 6: Locating Viscous Fan And Open-End Wrench 3312
Courtesy of AUDI OF AMERICA, INC.
Counter-hold fan pulley with pin wrench 3212 and tighten fan using open-end wrench 3312 and torque wrench (fan has left-hand thread).
Install noise insulation.
Install engine cover panel.

TIGHTENING TORQUES: TOOTHED (TIMING BELT)

Tightening torques

Nm/ft lb

Camshaft pulley

55/40

Idler

45/33

Cover for cylinder head

10/7

Outer ring of fan to radiator

10/7

Viscous fan - using torque wrench 1331 and open end wrench 3312⁽¹⁾

37/27

Viscous fan - using torque wrench without open end wrench 3312⁽¹⁾

70/52

Outer ring of fan to radiator

10/7

⁽¹⁾	Fan has LEFT-HAND threads.