Toothed belt, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tool T10020 Two Hole Pin Wrench

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Toothed Belt Tensioner T10020

Fig 2: Locking Tool T40098

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Locking Tool T40098

Removing

Fig 3: Removing Engine Cover

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Remove engine cover - arrows -.

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

Open cap of coolant expansion tank.

Fig 4: Identifying Exhaust Pipe Fasteners

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For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 5: Identifying Quick-Release Fasteners And Noise Insulation

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Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
Drain engine coolant → Cooling system, draining and filling
Bring lock carrier into service position → Lock carrier, moving into service position .

Fig 6: Disconnecting Coolant Pipe

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Disconnect coolant pipe - arrow -.

NOTE:

Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

Mark direction of rotation of ribbed belt.

Fig 7: Pivoting Belt Tensioner For Ribbed Belt To Relieve Tension On Ribbed Belt

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Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
Secure tensioning element using Locking Tool T40098.
Remove ribbed belt.

Fig 8: Setting Crankshaft And Camshaft To TDC At Cylinder 1

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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 9: Removing/Installing Vibration Damper/Belt Pulley

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Remove vibration damper/belt pulley.

Fig 10: Removing Bolts From Lower Section Of Toothed Belt Guard

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Remove bolts from lower toothed belt cover - arrows -.

Fig 11: Identifying Remaining Bolts From Toothed Belt Guard

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Remove remaining bolts from toothed belt guard - arrows - and remove toothed belt guard from engine.
Mark rotational direction of toothed belt.
Loosen tensioning roller and remove toothed belt.
Then, turn crankshaft back slightly.

Installing

NOTE:

When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged.
The engine must be no more than warm to touch.

Place toothed belt onto crankshaft sprocket (observe direction of rotation).
Secure lower toothed belt cover with two lower bolts.
Install vibration damper/belt pulley with new bolts.

Fig 12: Setting Crankshaft And Camshaft To TDC At Cylinder 1

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

Fig 13: Locating Toothed Belt

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

Fig 14: Identifying Tensioning Roller Is Properly Seated In Cylinder Head

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NOTE:

Be sure tensioning roller is properly seated in cylinder head.

Fig 15: Tensioning Toothed Belt

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Tension toothed belt. Do this by turning hex key at eccentric toward right (in direction of - arrow -) until notch is positioned above tab.
Release tension on toothed belt again.
Now tension toothed belt until notch and tab align.
Tighten tensioning roller nut.

Turn crankshaft 2 revolutions further in direction of engine rotation until 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.

Fig 16: Setting Crankshaft And Camshaft To TDC At Cylinder 1

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Check valve timing again.

If markings do not match:

Repeat valve timing adjustment.

If markings match:

Fig 17: Identifying Toothed Belt Guard Bolts

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Install toothed belt guard - arrows -.
Install crankshaft belt pulley → Crankshaft belt pulley, removing and installing .
Install ribbed belt → Ribbed belt, removing and installing .
Fill with coolant → Cooling system, draining and filling .

Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 18: Identifying Lock Carrier With Attachments

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Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.
Install noise insulation pan.

Install engine cover.

Torque specifications

Component		Nm
Toothed belt tensioning roller to cylinder head		23
Lower toothed belt cover to cylinder block		10 ³⁾
Center toothed belt guard to cylinder block		10 ³⁾
Vibration damper/belt pulley		10 + 90 ° ¹⁾²⁾
Torque support stop		28
¹⁾ Replace bolt ²⁾ 90 °Corresponds to a 1/4 turn ³⁾ Insert with locking fluid