Toothed belt tensioner
Withdrawal
1. Disconnect the negative cable from the battery.
2. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands. Remove the engine compartment bottom shield and disengage the front locking lug.
3. Remove the front bumper as described in Section 11.
4. Remove both headlights as described in Section 12.
5. Disconnect the cable from the hood lock, then unscrew the bolts of the cross member from the side panels of the engine compartment and the front brackets and remove it. Also remove the small air duct mounted on the radiator.
6. Turn off bolts of the top fastening of a radiator, and remove brackets (see section 2). Do not disconnect the hoses from the radiator.
7. The radiator now needs to be separated from the brackets on the right side and brought forward to create a working space in front of the engine. To do this, unscrew the bolts of the brackets on the right side of the radiator, on the 3D engine, remove the air ducts, then unscrew the bottom mounting nuts and bring the right side of the radiator forward. There is a special Audi bracket designed to hold the radiator away from the engine, but a metal strip or block of wood is a suitable replacement. Alternatively, you can remove the radiator (see section 2), which will create a much larger workspace.
8. Remove the auxiliary drive belt as described in Chapter 7.
9. Remove the thermoviscous fan assembly (see section 2). To do this, first unscrew the impeller fastening bolts, then block the flange/pulley and unscrew the thermoviscous coupling fastening nut. A homemade blocking tool can be made from a metal strip with two bolts screwed into one end (the distance between the centers of the holes on the flange/pulley is approx. 18 mm).
10. Turn off bolts and remove the mechanism of a tension of an auxiliary driving belt.
11. Turn the crankshaft and the installed engine to the TDC position as described in Chapter 2. This procedure involves removing the fuel pump drive belt and installing the camshaft lock rod. The TDC marks on the flywheel and on the high pressure fuel pump must be aligned.
12. Loosen the bolt on the toothed belt tensioner, then turn the gear clockwise to reduce belt tension and tighten the bolt.
13. Turn off a bolt and remove the mechanism of a tension from the block of cylinders (see illustration).
Installation
14. Install the tensioner and insert the bolt, but don't fully tighten it yet.
15. Install and tension the toothed drive belt (see chapter 4).
16. Install the auxiliary drive belt tensioner.
17. Install auxiliary drive belt (see chapter 7).
18. Install the thermoviscous fan assembly as described in Section 2.
19. Install the heatsink as described in Section 2.
20. Connect a cable of the lock of a cowl and establish a crossbar and an air duct.
21. Install headlights and front bumper.
22. Install the bottom guard and lower the vehicle to the ground.
23. Connect the battery.
Camshaft front sprocket
Withdrawal
24. Disconnect the negative cable from the battery.
25. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands. Remove the engine compartment bottom shield and disengage the front locking lug.
26. Remove the front bumper as described in Section 11.
27. Remove both headlights (Section 12).
28. Disconnect the cable from the hood lock, then unscrew the bolts of the cross member from the side panels of the engine compartment and the front brackets and remove it. Also remove the small air duct located on the radiator.
29. Turn off bolts of the top fastening of a radiator and remove brackets (see section 2). Do not disconnect hoses from the radiator.
30. The radiator now needs to be separated from the supports on the right side and brought forward to create a working space in front of the engine. To do this, unscrew the bolts of the brackets on the right side of the radiator, on the 3D engine, remove the air ducts, then unscrew the bottom mounting nuts and bring the right side of the radiator forward. There is a special Audi bracket designed to hold the radiator away from the engine, but a metal strip or block of wood is a suitable replacement. Alternatively, you can remove the radiator (see section 2), which will create a much larger workspace.
31. Remove the auxiliary drive belt as described in Chapter 7.
32. Remove thermoviscous fan assembly (Section 2).
33. Turn off bolts and remove the mechanism of a tension of an auxiliary driving belt.
34. Turn the crankshaft and set the engine to TDC as described in Chapter 2. This procedure involves removing the fuel pump drive belt and installing the camshaft lock rod. The TDC marks on the flywheel and on the high pressure fuel pump must be aligned.
35. Loosen the toothed belt tensioner bolt and move the mechanism to loosen the belt tension.
36. Remove the toothed belt from the camshaft sprocket and tensioner, move it to the side and tie it up so as not to bend or twist.
Warning: When the toothed belt is removed, do not rotate the crankshaft or camshaft, otherwise the piston heads and valves will be damaged.
37. Remove the camshaft cover as described in Chapter 8.
38. Loosen the camshaft sprocket bolt half a turn while holding the sprocket stationary with a suitable tool. To make it, use two pieces of steel strip (one is long, the other is short) and three nuts and bolts. One bolt connects two strips, so that a bifurcated grip is obtained, the remaining two bolts 3 are inserted into the ends of the grip and into the holes of the sprocket.
39. Gently knock the sprocket off the camshaft cone by carefully inserting a soft metal punch through the hole in the inner timing belt cover. Remove the bolt and sprocket from the camshaft, see illustrations).
Installation
40. Wipe the contact surfaces of the sprocket and camshaft.
41. Install the sprocket on the camshaft, insert the mounting bolt and tighten it at this stage by hand so that the sprocket can rotate.
42. Install and tension the timing belt (see chapter 4).
43. Install the camshaft cover, see Chapter 8.
44. Install the auxiliary drive belt tensioner and the belt itself (see chapter 7).
45. Install the thermoviscous fan assembly as described in Section 2.
46. Install the radiator (Section 2).
47. Connect the hood lock cable and install the cross member.
48. Install headlights and front bumper.
49. Install the bottom shield of the engine compartment and lower the car to the ground.
50. Connect the battery.
Rear camshaft sprocket
Withdrawal
51. Remove the fuel pump drive belt as described in Chapter 5.
52. Lock the rear sprocket by inserting a suitable tool into the sprocket holes, then loosen the bolt.
53. Remove the bolt and remove the sprocket from the end of the camshaft (see illustrations).
Installation
54. Install the sprocket on the end of the camshaft and install the bolt.
55. Install the fuel pump drive belt (see chapter 5).
56. Perform injection timing adjustment procedure as described in Section FOR.
Crankshaft sprocket
Withdrawal
57. Remove the toothed drive belt as described in Chapter 4.
58. Remove the sprocket from the end of the crankshaft (see illustration). If this fails, use two screwdrivers as levers.
Installation
59. Wipe the contact surfaces of the sprocket and crankshaft.
60. Install the sprocket on the end of the crankshaft, making sure that the protrusion on its inner side is in the groove on the shaft. If this fails, tap on it with a wooden block. Please note that the sprocket must not touch the oil pump housing.
61. Install the toothed drive belt as described in Chapter 4.
Fuel pump sprocket
62. See Section 3A.
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