Camshaft drive (Audi 100 C3)

Camshaft Drive Parts

• 1 - water pump pulley;
• 2 - water pump pulley mounting bolt;
• 3 - crankshaft pulley mounting bolt;
• 4 - crankshaft pulley;
• 5 - belt;
• 6 - plugs;
• 7 - lower camshaft drive cover;
• 8 - Upper camshaft drive cover;
• 9 - camshaft drive belt;
• 10 - rear cover of the camshaft drive;
• 11 - intermediate shaft gear;
• 12 - intermediate shaft gear mounting bolt;
• 13 - crankshaft gear;
• 14 - crankshaft gear mounting bolt;
• 15 - camshaft drive belt tensioner;
• 16 - tensioner mounting nut

Adjusting and checking the tension of the camshaft drive belt

• 1 - camshaft drive belt tensioner;
• 2, 3 - spanners;
• 4 - camshaft toothed wheel;
• 5 - camshaft drive belt;
• 6 - intermediate shaft gear

Disassembly

1. Remove the upper camshaft drive cover (see Fig. Camshaft Drive Parts).

2. Loosen the mounting bolts and remove the water pump pulley.

3. Set the piston of the 1st cylinder to TDC of the compression stroke (both valves are closed). The mark on the crankshaft pulley must be aligned with the arrow on the lower camshaft drive cover.

4. Remove the four bolts and crankshaft pulley.

5. Remove the lower camshaft drive cover.

6. Loosen the belt tensioner mounting nut and use a wrench to turn the belt tensioner eccentric shaft counterclockwise to loosen the belt tension.

7. Remove the belt from the crankshaft, camshaft and intermediate shaft gears and from the tensioner mechanism tensioner.

8. Unscrew the nut and remove the tensioner.

9. Loosen the bolt and remove the intermediate shaft gear, remove the key.

10. Loosen the bolt and remove the crankshaft gear, remove the key.

11. Loosen the bolt and remove the toothed wheel from the camshaft, remove the key.

12. Loosen the bolts and remove the rear cover of the camshaft drive.

Assembly and adjustment

1. Install the rear camshaft drive cover and tighten the bolts that secure it.

2. Insert the key into the groove on the crankshaft and install the gear. Apply sealant to the thread of bolt 14, screw in the bolt with the washer and tighten to a torque of 200 N·m (20.0 kgf·m).



3. Insert the key into the groove on the camshaft, install the toothed wheel, screw in the bolt with the washer and tighten to a torque of 80 N·m (8.0 kgf·m). The mark on the toothed wheel must coincide with the upper plane of the cylinder head cover gasket on the left side of the engine.



4. Insert the key into the groove of the intermediate shaft, install the gear wheel, screw in bolt 12 with a washer and tighten to a torque of 80 N·m (8.0 kgf·m).

5. Install the camshaft drive belt tensioner mechanism.



6. Temporarily install pulley 4 of the crankshaft on gear 13. Piston of the 1st cylinder should be at TDC. Turn gear 11 of the intermediate shaft so that the mark on it aligns with the mark on pulley 4 of the crankshaft, as shown in the figure.

7. Put on belt 9.

8. Turn key 3 (see fig. Adjusting and checking the tension of the camshaft drive belt) mechanism 1 of tensioning the belt 5 clockwise to pre-tension the belt. Check that the TDC marks have not moved. Turn mechanism 1 of tensioning further clockwise, tensioning belt 5 so that it can be turned 90°, grasping it with two fingers in the middle between the camshaft and intermediate shaft. Holding the tensioning mechanism with key 3, tighten its fastening nut with key 2.

9. Remove crankshaft pulley 4. Install lower cover 7 of the camshaft drive (see Fig. Camshaft Drive Parts).

10. Install the crankshaft pulley, tighten bolts 3 to a torque of 20 N·m (2.0 kgf·m).



11. Install the water pump pulley.

12. Install the upper camshaft drive cover.

(This publication is borrowed from the resource AudiManual.ru)