Toothed belt, removing and installing: Removing

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.

Lock carrier in service position. Refer to Lock carrier, moving into service position .
Ribbed belt removed. Refer to Ribbed belt, removing and installing .
Ribbed belt tensioner removed. Refer to Ribbed belt tensioner, removing and installing .

Fig 1: Removing Ribbed Belt Gear Of Vane Pump Using 3212 Spanner Wrench As Retainer

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove ribbed belt gear of power steering pump (arrows) using 3212 spanner wrench as retainer.

Fig 2: Removing Bolts, Harmonic Balancer And Thrust Washer

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove 8 bolts -1-.
Remove harmonic balancer -2- and thrust washer -3-.

NOTE:

Thrust washer -3- is only installed on toothed belt gear with part number 06C 105 063 A.
No thrust washer must be installed for toothed belt gear with part number 06C 105 063 B.

Fig 3: Unscrewing Bolts And Removing Toothed Belt Guards

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unscrew bolts -1 to 12- and remove toothed belt guards.

Fig 4: Removing Rear Engine Cover

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rear engine cover (arrows).

Fig 5: Removing Coolant Hoses

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove coolant reservoir (arrow)
Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.
Tie coolant expansion tank with connected coolant hoses -1 to 3- to side.

Fig 6: Removing Air Filter Housing

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove air filter housing (arrows).
Disconnect electrical harness connector -1- at Mass Air Flow (MAF) sensor.
Remove air guide hose -2- together with Mass Air Flow (MAF) sensor.

Fig 7: Identifying Bolts, Hose From Line Of Secondary Air Injection

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -1- and -3-.
Disconnect hose -4- from line of secondary air injection.
Pull out guide tube for oil dipstick 2 from the oil pan (upper part) toward top and swing it forward for removal.

Fig 8: Removing Bolts At Right Cylinder Head Cover & Disconnecting Electrical Harness Connectors

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -5- and -6- at right cylinder head cover.
Disconnect electrical harness connectors -1- to -4-.
Remove ignition coils (arrows).

Fig 9: Right Cylinder Head Cover Crankshaft Housing Venitilation Hose

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove hose of crankshaft housing ventilation (arrow).
Unscrew bolts for right cylinder head cover in sequence -12- to -1-.
Remove cylinder head cover.

Fig 10: Removing Bolts At Left Cylinder Head Cover & Disconnecting Electrical Harness Connectors

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -4- and -5- at left cylinder head cover.
Disconnect electrical harness connectors -1- to -3- and -6-.
Remove ignition coils (arrows).

Fig 11: Left Cylinder Head Cover Crankshaft Housing Ventilation Hose

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove hose of crankshaft housing ventilation (arrow).
Unscrew bolts for left cylinder head cover in sequence -12- to -1-.
Remove cylinder head cover.

WARNING:

Turning of the engine must only occur in direction of engine rotation (clockwise) at the crankshaft.

Fig 12: Turning Engine Until Cams At Intake And Exhaust Camshaft Of Cylinder 3 (Right Cylinder Bank) Point Upward Uniformly

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Turn engine until cams (arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder bank) point upward uniformly.

NOTE: Turn engine at crankshaft central bolt.

Fig 13: Inserting T40030 Camshaft Adjuster Gauge At Camshafts Of Right Cylinder Head

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert T40030 camshaft adjuster gauge at camshafts of right cylinder head.

NOTE: Slightly turn crankshaft back and forth so that the claw of T40030 camshaft adjuster gauge can properly grab the camshafts.

Spread T40030 camshaft adjuster gauge with threaded shaft (tightening torque 10 Nm) until it is seated without axial play.

Fig 14: Inserting T40030 Camshaft Adjuster Gauge At Left Cylinder Head

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert T40030 camshaft adjuster gauge at left cylinder head in same manner.
If installed, disconnect electrical harness connector at after-run coolant pump.
Unscrew sealing plug of TDC mark at cylinder block.

Fig 15: Threading T40026 Locking Pin Into Hole Of Removed Sealing Plug

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Thread T40026 locking pin into hole of removed sealing plug and tighten.

NOTE: Slightly turn crankshaft back and forth to do so.

NOTE: Catch escaping oil using a rag.

Fig 16: Prying Off Securing Rings For Caps At All Camshaft Gears

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry off securing rings -1- for caps -2- at all camshaft gears.

Fig 17: Locating Bolts For Camshaft Gears

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen but do not remove bolts -1- to -4- for camshaft gears.

NOTE: The bolts remain loosely threaded in.

Fig 18: 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

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 T40011 pin can be inserted into bore of pistons and housing.

NOTE:

The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure.
Mark rotational direction of toothed belt. Reversing the direction in which it runs can ruin it.

Fig 19: Locating Bolt Of Eccentric Pulley

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen bolt (arrow) of eccentric pulley.
Remove toothed belt.