Toothed Belt, Without Divided Toothed Belt Guard

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a cover and guard is divided in engine bracket area. Toothed belt, vehicles with divided toothed belt guard, removing and installing TOOTHED BELT, WITH DIVIDED TOOTHED BELT GUARD .

Special tools and workshop equipment required

Engine Support Bridge 10 - 222 A
Spindle 10 - 222 A /11; quantity: 2
Special Hook 10 - 222 A /20; quantity: 2
Additional Hooks (2)10 - 222 A /2
Engine Support Basic Set T40091
Engine Support Supplement Set T40093 with Engine Supplement Left and Right T40093/3-2 and Engine Supplement Left and Right T40093/3-3
Toothed Belt Tensioner T10020
Locking Pin T10060A

Removing

-- Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Fig 1: Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector, Clips & Front Air Intake Connector On Lock Carrier

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-- Open clips -1 and 2- and remove air guide hose from MAF sensor.

-- Remove front air intake connector on lock carrier -4-.

-- Remove engine cover.

WARNING:

Cover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.

-- Open cap of coolant expansion tank.

-- Remove center noise insulation fasteners -1 to 4-.

Fig 2: Center Noise Insulation Fasteners And Center Noise Insulation Panel

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-- Remove the right noise insulation -arrows-.

Fig 3: Identifying Right Noise Insulation -Arrows-, Removal

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-- Remove noise insulation frame -arrow-.

Fig 4: Identifying Noise Insulation Frame, Removal

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-- Remove the bolts -arrows- and disconnect charge air pipe with hoses.

Fig 5: Identifying Charge Air Pipe Bolts

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-- Remove the bolts -1 to 3- and the pendulum support.

Fig 6: Identifying Pendulum Support & Bolts

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-- Drain the coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.

-- Mark the fuel line -1- and the Evaporative Emission (EVAP) line -2-.

Fig 7: Fuel Line, EVAP Line And Fuel Tank

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-- Disconnect fuel line -1-.

-- Disconnect the EVAP line -2-.

-- Disconnect the EVAP line to fuel tank -3-.

-- Remove EVAP canister upward in direction of -arrow-.

-- Loosen the coolant hose from the retainer -1-.

Fig 8: EVAP Filter And Retainer

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-- Remove bracket for EVAP filter -arrows-.

-- Unbolt the filler tube for the windshield washer fluid reservoir -1-.

Fig 9: Windshield Washer Fluid Reservoir And Bolts

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-- Remove the retaining clip, by removing bolts -2 and 3-.

-- Disconnect the electrical connector -1- from coolant level indicator.

Fig 10: Coolant Expansion Tank And Electrical Connector

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-- Remove coolant expansion tank -arrows-.

-- Disconnect coolant pipe -arrow-.

Fig 11: Coolant Pipe

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-- Remove the ribbed belt. Refer to RIBBED BELT .

-- Remove ribbed belt tensioner -arrows-.

Fig 12: Ribbed Belt Tensioner Bolts

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-- Remove EVAP canister bracket.

-- Loosen coolant pipe -arrows-.

Fig 13: Locating Coolant Pipes

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-- Disengage shift cable -arrow-.

Fig 14: Disengage Shift Cable

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-- Position the 10 - 222 A on fender bolting edge with the following tool parts:

Fig 15: Position 10 - 222 A On Fender Bolting Edge

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Engine brackets 10 - 222 A /1, quantity: 2
Engine support bridge 10 - 222 A
Spindle 10 - 222 A /11 (spindle faces forward)
Additional hooks 10 - 222 A /2
Adapter 10 - 222 A /20
Connectors T40091/3 qty. 2

-- Engage spindle 10 - 222 A /11 with 10 - 222 A /2 and special hook 10 - 222 A /20 on transmission lifting eye.

-- Tension engine/transmission subframe with spindle.

-- Install adapter T40093/3-2 (left) and T40093/3-3 (right) on supports T40093/3.

Fig 16: Installing Engine Support Bridge Adapter

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-- Remove ground (GND) line from left longitudinal member.

-- Remove left and right connecting bolt for front section of the long member.

-- Secure adapter to the long members with bolts -arrow- removed earlier.

NOTE:

The illustration shows the left side of the vehicle.

Fig 17: Place Square Pipes As Shown Illustration

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-- Slide support T40091/2 into both connectors T40093/4 with slide T40093/5.

Fig 18: Slide support T40091/2 into both connectors T40093/4 with slide T40093/5

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WARNING:

Risk of accident due to loose engine support bridge spindles.

Secure the T40091/2 with connector pins and splints T40093/4.
Secure connector and supports with clamping bolts.

-- Install 10 - 222 A /11 with 10 - 222 A /20 on slide and on engine lifting eye.

-- Tension engine/transmission subframe by evenly tightening the 2 spindles.

-- Remove bolts from assembly mount/engine support -arrows- remove assembly mount completely.

Fig 19: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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CAUTION:

When lifting the engine with the 10-222A, make sure that no components/hoses are damaged, overstressed or torn off.

-- Lift the engine with the 10-222A so far that both upper bolts -1 and 2- of the engine support can be loosened and removed.

Fig 20: Identifying Engine Bracket Bolt

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-- Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard.

Fig 21: Bringing Camshaft Gear To Marking For TDC Cylinder 1

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-- Remove vibration damper/belt pulley.

Fig 22: Identifying Vibration Damper/Belt Pulley

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-- Remove the bolts from lower section of the toothed belt guard -arrows-.

Fig 23: Identifying Bolts From Lower Section Of Toothed Belt Guard

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-- Loosen the lower bolts -3- and remove the engine support downward and out.

Fig 24: Identifying Engine Bracket Bolt

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-- Remove remaining bolts from toothed belt guard -arrows- and remove toothed belt guard from engine.

Fig 25: Identifying Remaining Bolts From Toothed Belt Guard

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-- Mark rotational direction of toothed belt.

-- Loosen tensioning roller and remove toothed belt.

-- Then, turn the crankshaft back slightly.

Installing

For the correct tightening specifications, refer to TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW .

NOTE:

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

The engine must be no more than warm to touch.

-- Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).

-- Secure the lower toothed belt guard with the two lower bolts.

-- Install vibration damper with new bolts.

-- Set the crankshaft and camshaft to TDC at cylinder 1 -arrows-.

Fig 26: Bringing Camshaft Gear To Marking For TDC Cylinder 1

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-- Route toothed belt in the sequence: Tensioning roller, camshaft gear, coolant pump and last over the relay pulley -arrow-.

Fig 27: Identifying Routing Of Toothed Belt

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NOTE:

Be sure tensioning roller is properly seated in cylinder head.

Fig 28: Identifying Tensioning Roller Is Properly Seated In Cylinder Head

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-- Tension toothed belt. Do this by turning the hex key at the eccentric toward the right (in direction of -arrow-) until the notch is positioned above the tab.

Fig 29: Identifying Tensioning Of Toothed Belt

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-- Release tension on toothed belt again.

-- Now tension toothed belt until notch and tab align.

-- Tighten mounting nut.

-- Turn the crankshaft 2 revolutions further in direction of engine rotation until the engine is positioned at TDC again. For this it is necessary that the last 45° (¹ /₈ rotation) is turned without interruption.

-- Check tension of toothed belt again. Specified value: Tab and notch align.

-- Check the valve timing again.

Fig 30: Bringing Camshaft Gear To Marking For TDC Cylinder 1

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If the markings do not match:

-- Repeat valve timing adjustment.

If the markings match:

-- Install the toothed belt guard -arrows-.

Fig 31: Identifying Toothed Belt Guard Bolts

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NOTE:

Note different length of bolts. Bolt -3- is approximately 25 mm shorter than bolts -1 and 2-.

Fig 32: Identifying Engine Bracket Bolt

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-- Insert the lower bolt -3- into the engine support.

-- Install the engine support from below onto the cylinder block and hand-tighten the bolt.

-- Lift the engine with the 10-222A so far that both upper bolts -1 and 2- can be screwed in.

-- Tighten all bolts.

-- Lower engine to installation position.

-- Install subframe mount for engine completely.

-- Fasten engine assembly mount to engine support -arrows-, bringing the contact surfaces into contact using the 10-222A.

Fig 33: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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-- Adjust the engine mounts. Refer to SUBFRAME MOUNT, ADJUSTING .

-- Connect fuel hoses to connections. Make sure connector couplings are securely fastened.

-- Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS, ASSEMBLING .

-- Install coolant expansion tank.

-- Install noise insulation.

-- Install the engine cover.

-- Install vibration damper. Refer to VIBRATION DAMPER .

-- Install the ribbed belt. Refer to RIBBED BELT .