Toothed belt, removing and installing

WARNING: This page is about a different car, the 2006 Audi A8, 2005 Audi A8, and 2004 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Toothed Belt, Removing And Installing

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Special tools, testers and auxiliary items required

Tightener pulley wrench T40009
Crankshaft Holder 3242
Torque wrench V.A.G 1783
Ratchet 1/4" VAS 6234

Puller T40001 with claws T40001/2
Camshaft locator T40005

Fig 2: Securing Pin T40011

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Securing pin T40011

Fig 3: Spanner Wrench 3212

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Spanner Wrench 3212

Toothed belt, removing

NOTE:

Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode → 43 - Self Leveling Suspension .

Remove front bumper → 63 - BUMPERS .
Remove lock carrier → 50 - BODY - FRONT .
Remove ribbed belt → Ribbed belt, removing and installing

Fig 4: Removing Engine Cover

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Remove engine cover - 2 - upward.
Remove upper toothed belt guard at left and right.

CAUTION: Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).

Turn crankshaft at center bolt of toothed belt gear in direction of engine rotation to TDC Cyl. 5 5 marking.

Fig 5: Identifying Notch Aligns With Marking

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Notch - B - aligns with marking - A -

NOTE:

Turning over engine is performed at the center bolt of the crankshaft.

Check position of camshafts:

Fig 6: Identifying Large Holes On Securing Plates At Camshaft Gears Aligns On Inside

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The large holes - arrows - on securing plates at camshaft gears must align on inside.

In case they do not align, turn one more rotation.

Fig 7: Disconnecting Water Pipe From Oil Pan

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Disconnect water pipe - arrow - from oil pan.

Fig 8: Disconnecting Water Pipe From Engine Block

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Disconnect water pipe from engine block - arrow -.

Fig 9: Removing Locking Bolt Of TDC Marking At Upper Part Of Oil Pan

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Remove locking bolt - arrow - of TDC marking at upper part of oil pan.

NOTE:

In the crankshaft, a TDC bore is located exactly behind the locking bolt (can be felt by touch).

CAUTION: Do not rotate crankshaft while touching TDC mark with finger - danger of injury.

Fig 10: Installing Crankshaft Holder 3242 In Hole For Removed Locking Bolt

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Install crankshaft holder 3242 in hole for removed locking bolt.

Fig 11: Removing Vibration Damper Of Crankshaft After Removing 8 Attachment Bolts

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Remove vibration damper of crankshaft after removing 8 attachment bolts - 1 -.
Remove center toothed belt cover.

Fig 12: Separating Torque Support From Torque Support Valve N382

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Separate torque support - arrow - from torque support valve N382.

Fig 13: Removing Bracket For Torque Support Valve N382

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Remove bracket for torque support valve N382 - arrows -.

Fig 14: Using Hex Socket Wrench To Turn Toothed Belt Tensioner

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Using an 8 mm hex socket wrench, turn toothed belt tensioner in direction of - arrow - until tensioning lever pushes tensioner together far enough so that locking pin T40011 can be inserted into bores of pistons and housing.

NOTE:

When inserting, bracket for torque support valve N382 remains installed. The locking pin can be guided through a hole in the bracket to be inserted into the holes in the tensioner.
The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure.
Mark direction of rotation of toothed belt. Reversed running direction can cause damage.

Fig 15: Locating Bolt Of Eccentric Pulley

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Loosen bolt - arrow - of eccentric pulley.

Fig 16: Installing Camshaft Adjustment T40005 In Locking Plates Of Camshafts

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Install camshaft adjustment T40005 in locking plates of camshafts.
Loosen both camshaft gear bolts approx. 5 turns.

NOTE:

The camshaft adjustment T40005 serves as a retainer.

Remove camshaft adjustment T40005.

Fig 17: Removing Left/Right Camshaft Gears From Cone Using Puller T40001 With Claw T40001/2

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Remove left and right camshaft gears from cone using Puller T40001 with Claw T40001/2.
Remove toothed belt.

CAUTION: Check gears after removing. If dents are visible, replace camshaft gears.

Installing (Adjusting valve timing)

NOTE:

When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged.

Fig 18: Replacing Bolts For Camshaft Gears And Securing Plates

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Replace bolts - 1 - for camshaft gears and securing plates - 2 -.
Grease threads and head seating surfaces of bolts for camshaft gears.
Install bolts far enough so that they can still just be turned and do not cant.
Observe proper seating of securing plates on camshafts.

Before installing toothed belt, make sure crankshaft and camshafts are set to TDC cylinder 5:

Fig 19: Identifying Large Holes On Securing Plates At Camshaft Gears Aligns On Inside

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The large holes - arrows - on securing plates at camshaft gears must align on inside.

Fig 20: Installing Crankshaft Holder 3242 In Hole For Removed Locking Bolt

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Crankshaft holder 3242 must be installed.

Fig 21: Toothed Belt Routing Sequence

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Route toothed belt in the following sequence: Toothed belt gear crankshaft - 5 - , eccentric pulley - 4 - , tensioner - 6 - , toothed belt gear left camshaft - 3 - , coolant pump - 2 -.
At last, place toothed belt on toothed belt gear of right camshaft - 1 -.

Fig 22: Turning Tensioning Lever Twice In Direction Of To Pretension Toothed Belt

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Turn tensioning lever twice at 40 Nm in direction of - arrow - to pretension toothed belt.

NOTE:

In the next two illustrations, depicted with torque support bracket removed, for the sake of illustration.

Fig 23: Inserting Hex Socket Wrench Flat Between Tensioning Lever And Piston Of Tensioner

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Insert a 5 mm hex socket wrench flat between tensioning lever - 1 - and piston - 2 - of tensioner.

Fig 24: Locating Toothed Belt Eccentric Pulley

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Tighten toothed belt by turning eccentric pulley using tightener pulley wrench T40009 and turn torque wrench V.A.G 1783 using ratchet VAS 6234 indirection of - arrow - and hold.

Protection torque 6 Nm

Tighten eccentric pulley.

NOTE:

Make sure that position does not change while tightening.

Fig 25: Installing Camshaft Adjustment T40005 In Locking Plates Of Camshafts

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Insert camshaft adjustment T40005 into securing plates of both camshafts.

Press in camshaft adjustment as far as possible.

Tighten camshaft gears.

NOTE:

The camshaft adjustment T40005 serves as a retainer.

Remove camshaft adjustment T40005.
Remove 5 mm hex socket wrench.

Fig 26: Turning Tensioning Lever Using Hex Socket Wrench Until Locking Pin T40011 Can Be Pulled Out

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Turn tensioning lever using 8 mm hex socket wrench in direction of - arrow - until Locking Pin T40011 can be pulled out.
Remove crankshaft holder 3242.
Turn crankshaft two complete rotations in direction of engine rotation until crankshaft stands at TDC cyl. 5 again.

Fig 27: Identifying Large Holes On Securing Plates At Camshaft Gears Aligns On Inside

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The large holes - arrows - on securing plates at camshaft gears must align on inside.

Fig 28: Checking Dimension Between Tensioning Lever And Tensioner Housing

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Check dimension - a - between tensioning lever and tensioner housing.

Dimension - a - = 5.0 ± 1.0 mm

NOTE:

If dimension - a - is not obtained, repeat adjustment.

Fig 29: Installing Crankshaft Holder 3242 In Hole For Removed Locking Bolt

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To check timing, bolt crankshaft holder 3242 in bore at upper part of oil pan again.

Fig 30: Installing Camshaft Adjustment T40005 In Locking Plates Of Camshafts

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Check camshaft positions using camshaft adjustment T40005.

NOTE:

If camshaft locator cannot be inserted, repeat adjustment.

Remove camshaft adjustment T40005 from both cylinder heads.
Remove crankshaft holder 3242.
Bolt locking bolt of TDC marking into upper part of oil pan using new sealing ring.

Further installation is in reverse order of removal, note the following:

NOTE:

Replace gaskets, seals and O-rings.
Secure all hose connections using hose clamps appropriate for the model type .

Install ribbed belt → Ribbed belt, removing and installing .
Install lock carrier with attachments → 50 - BODY - FRONT .
Fill with coolant.
Install torque support → Torque support (with torque support valve N382), assembly overview .

NOTE:

Only reuse drained coolant if cylinder head or engine block was not replaced.
Dirty coolant must not be re-used.

Torque specifications

Component		Nm
Eccentric pulley to cylinder block		45
Camshaft sprocket to camshaft		55
Sealing plug in upper section of oil pan		35
Vibration damper to crankshaft gear		22
Tension roller for ribbed belt		43