Installing (adjusting valve timing)

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Camshafts aligned using T40030 camshaft adjuster gauge
Crankshaft aligned using T40026 locking pin
Camshaft gears loosened.

NOTE:

Replace gaskets, O-rings and self-locking bolts.
When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged.

Fig 1: Locating Bolts For Camshaft Gears

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bolt in camshaft gears -1- to -4- far enough so they can still just be turned without canting.
Install toothed belt as depicted in illustration.

For exact valve timing adjustment, toothed belt must make exact contact with front edge of all toothed belt gears.

Fig 2: Using 3387 Pin Wrench To Turn Eccentric Pulley Until Handle Of Pin Wrench Is Exactly Above Center Axle Of Coolant Pump Gear

GW00017653

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using 3387 pin wrench, turn eccentric pulley -1- in clockwise direction until handle of pin wrench is exactly above center axle of coolant pump gear -2-.
Hold pin wrench in this position and tighten bolt -3- to 45 Nm.

Fig 3: Pre-Tension Toothed Belt

GW00017654

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place torque wrench horizontally on socket-head of tensioning lever.
Turn with 45 Nm in direction of arrow to pre-tension toothed belt.

Fig 4: Turning Toothed Belt Tensioner Until Tensioning Lever Pushes Tensioner Together Far Enough So That T40011 Pin Can Be Inserted Into Bore Of Pistons And Housing

GW00017651

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Using 8 mm socket head wrench, turn toothed belt tensioning roller in direction of arrow until T40011 pin can pulled out.

Fig 5: Tensioning Toothed Belt

GW00017655

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place torque wrench horizontally on socket-head of tensioning lever.
Turn with 25 Nm in direction of arrow to tension toothed belt.

Fig 6: Inserting T40028 Socket At Camshaft Adjuster Of Exhaust Camshaft On Left Cylinder Bank

GW00017656

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert T40028 socket at camshaft adjuster of exhaust camshaft on left cylinder bank.
Turn rotor of camshaft adjuster clockwise to 10 Nm up to stop (arrow).

Fig 7: Turning Rotor Of Camshaft Adjuster At Right Cylinder Bank Clockwise

GW00017657

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn rotor of camshaft adjuster at right cylinder bank clockwise to 10 Nm up to stop (arrow).
Tighten bolts for all four camshaft gears to 100 Nm.

Fig 8: Prying Off Securing Rings For Caps At All Camshaft Gears

GW00017649

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert caps -2- with new O-rings -1- at camshaft gears and secure them with securing ring.
Remove T40030 camshaft adjuster gauge.
Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O-ring into cylinder block.

Installation is reverse of removal, noting the following:

Install cylinder head covers. Refer to Installing for Left cylinder head cover or Installing for Right cylinder head cover.
Install toothed belt guards. Refer to Toothed belt cover, removing and installing .
Install harmonic balancer. Refer to Vibration damper, removing and installing .
Install ribbed belt. Refer to Installing .