Table of contents: Removal ↓ Installation ↓
Removal
Loosen the generator mounting bolts and remove the drive belt.
Remove the crankshaft pulley.
Remove the timing belt protective covers.
Disconnect the high voltage wire harness.
Remove the spark plugs from the cylinder head sockets.
Turn the crankshaft to the TDC position of the compression stroke of the piston of the 1st cylinder, aligning the mark on the flywheel with the installation protrusion on the clutch housing and placing the mark on the camshaft pulley at the level of the cylinder head gasket (see photo).
Compression stroke of piston 1st cylinder. Marks for adjusting valve timing. The arrows show the marks on the crankshaft pulley and on the intermediate shaft toothed pulley, the mark on the camshaft pulley on the left side at the level of the cylinder head gasket plane
Loosen the tension roller axle mounting nut.
Remove the camshaft drive toothed belt.
Installation
Note: Do not turn the camshaft when any of the pistons is at TDC.
Set the camshaft to the TDC position of the ignition stroke of the piston of the 1st cylinder, placing a mark on the camshaft pulley at the level of the cylinder head gasket.
Install the intermediate shaft toothed pulley in the correct position, aligning the mark on it with the TDC mark of the 1st cylinder piston on the crankshaft pulley.
Set the crankshaft to the position corresponding to the TDC of the compression stroke of the piston of the 1st cylinder according to the marks on the flywheel and on the clutch housing.
Place the timing belt on the pulleys.
Adjust the belt tension by turning the tension roller on the axle in the direction opposite to the direction of rotation of the toothed belt.
To tension the timing belt, turn the tension roller in the direction shown by the arrow
Turn the crankshaft two revolutions and check that the timing belt tension is adjusted correctly.
Remove the crankshaft pulley and install the timing belt protective covers.
Install the crankshaft pulley.
Install the alternator drive belt and adjust its tension.
Tighten the generator mounting bolts.
Screw in the spark plugs and connect the high tension wires.
Check and, if necessary, adjust the ignition timing.
A link to the original source is available on the website AUDImanual