High Pressure Pump Toothed Belt, Removing And Installing: Installing

WARNING: This page is about a different car, the 2011 Audi Q7, 2010 Audi Q7, and 2009 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Install in reverse order of removal. Note the following:

-- Remove noise insulation.

-- Insert the Crankshaft SocketT40058 guide pins as follows:

Fig 1: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

Fig 2: Identifying TDC With Special Tool Adapter T140058

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CAUTION:

Components could be destroyed by the camshaft timing chains jumping off.

Turn crankshaft only in direction of engine rotation -arrow-.

-- Use the Crankshaft SocketT40058 to rotate the crankshaft to "TDC".

As shown in the illustration, the marking -arrow- must be vertical on the center of the crankshaft.

Fig 3: Identifying Vertical Mark -Arrow- On Center Of Crankshaft
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-- Remove the air guide hose.

-- Remove the plug -arrow- behind the right cylinder head.

Fig 4: Identifying Plug -Arrow- Behind Right Cylinder Head

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NOTE:

To provide a better illustration, installed position is shown with engine removed from behind.

-- Check to see if the groove -arrow- in the camshaft flange can be seen through the sealing plug hole -1-.

-- Shine a small flashlight in the sealing plug hole to see.

Fig 5: Identifying Groove -Arrow- In Camshaft Flange And Plug Hole -1-

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NOTE:

The camshaft flange is shown without chain drive and without timing chain guard to make the illustration better.

-- Turn the crankshaft 360 degrees in the direction of engine rotation if the groove is not under the hole.

NOTE:

To collect escaping engine oil, place a clean cloth under the upper part of the oil pan.

Fig 6: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Remove the sealing plug -arrow- from the upper section of the oil pan.

Fig 7: Identifying Crankshaft Holder 3242

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WARNING:

Risk of injury when touching "TDC" hole with finger.

Do not rotate crankshaft -1-.

-- Install the Crankshaft Holder3242 in the hole and tighten to 20 Nm. Turn the crankshaft back slightly to completely center the bolt, if necessary.

NOTE:

The high pressure pump and its toothed belt gear must be installed securely before installing the toothed belt.

-- Stop the high pressure pump toothed belt wheel with the High Pressure Pump Sprocket Locking ToolT40135.

Fig 8: Identifying Locking Tool T40135 For High Pressure Pump Toothed Belt

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NOTE:

Stop the high pressure pump toothed belt using the High Pressure Pump Sprocket Locking ToolT40135 before installing the toothed belt. (Do not allow the toothed belt to swing!).

The hole -arrow in the toothed belt sprocket- is situated in the -3-'o'clock-position-.

Fig 9: Identifying Hole -Arrow In Toothed Belt Sprocket- Situated At -3 O'clock Position-

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Insert the High Pressure Pump Sprocket Locking ToolT40135 all the way in.

Fig 10: Identifying Locking Tool T40135 For High Pressure Pump Toothed Belt

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-- Check the installation position of the toothed belt tensioning roller:

Fig 11: Identifying Hex Mount -Arrow 1- And Claw -Arrow 2-

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The claw -arrow 2- must fit into the recess in the high pressure pump bracket.

The tension roller must be relieved of tension and the hex mount -arrow 1- faces downward.

-- Install the toothed belt.

Fig 12: Identifying Toothed Belt Tensioner Bolt -1-, Toothed Belt Sprocket Bolt -2- And Locking Tool T40135

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-- Install the toothed belt tension roller bolt -1- without using force until the eccentric pulley for the tensioning roller can be turned without tipping.

-- Install the toothed belt drive sprocket bolt -2- far enough until sprocket can be turned without tilting.

-- Stop the high pressure pump toothed belt wheel with the High Pressure Pump Sprocket Locking ToolT40135.

-- Continue to pretension the toothed belt tensioning roller the direction of the -arrow- with the hex socket wrench until the hex mount is in the -1-'o' clock-position-.

Fig 13: Identifying Hex Socket And Toothed Belt Tensioning Roller

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CAUTION:

Never remove while in the "12-'o'clock-position" or above.

-- Release the toothed belt tensioning roller to the point where the hex mount is in the -3-'o' clock position- in direction of -arrow-.

Fig 14: Identifying Toothed Belt Tensioning Roller Aligned With Hex Mount

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-- Pretension the toothed belt tensioning roller from the -3-'o' clock-position- in direction of -arrow- to the point where the tab -1- and the notch -2- are exactly opposite each other.

Fig 15: Identifying Toothed Belt Tensioning Roller With Tab -1- And Notch -2- Held In Position

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-- Hold the toothed belt tensioning roller in this position and tighten the bolt -arrow- -item 12- OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT.

Fig 16: Identifying Toothed Belt Tensioning Roller And Bolt -Arrow-

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-- Tighten the toothed belt drive wheel bolt -1- using the Wrench - Pin Type3036 -item 11- OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT.

Fig 17: Identifying Toothed Belt Drive Sprocket Bolt -1- And 3036

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-- Remove the Crankshaft Holder3242.

Fig 18: Identifying Crankshaft Holder 3242

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-- Install the bolt -arrow- for the "TDC" marking into the upper section of the oil pan. .

Fig 19: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Insert the Crankshaft SocketT40058 guide pins as follows:

Fig 20: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

Fig 21: Identifying TDC With Special Tool Adapter T140058

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CAUTION:

Components could be damaged by the camshaft timing chain jumping off.

Turn crankshaft only in direction of engine rotation -arrow-.

-- Turn the crankshaft one turn using the Crankshaft SocketT40058.

-- Check the toothed belt tension:

Fig 22: Identifying Tab -1- Aligned With Notch -2-

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The tab -1- must align with the notch -2-.

-- If the specified value is not reached, adjust the toothed belt tension one more time.

Assembly is performed in reverse order.

Tightening specifications. Refer to OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT