MOT No. 40
It has already been mentioned that the alternator V-belt must be replaced in a 4-cylinder engine manufactured before August 91. However, the following applies to the replacement of other V-belts.
Replacement (poly-) V-belt in a 4-cylinder engine
A new V-belt must never be «drag» on the pulleys with a screwdriver, because the resulting cuts, so to speak, predetermine the next break in the belt.
Loosen the old belt for replacement.
Now you can safely remove it from the pulleys, and the new belt can be conveniently put on them.
Left: The illustration shows the installation position of the air conditioning compressor (1) 4-cylinder engine. The 4-cylinder engine has an additional front-mounted pulley (2), where the belt tension is adjusted.
Right: details of the crankshaft pulley on models with a 4-cylinder engine and air conditioning. The numbers indicate:
1 - pulley hub;
2 - extra shims;
3 - the front half of the pulley;
4 - adjusting washers;
5 - rear half of the pulley.
To remove the V-ribbed belt in a 5-cylinder engine, use a wrench, as shown in the figure, installed in the tensioner (2) and rotated in the direction of the arrows. To secure the tensioner when the belt is loose, insert a punch (1) into the hole intended for it, as well as into the hole in the panel below.
This shows the position of the V-ribbed belt in a vehicle with a five-cylinder engine (without air conditioning). Parts and pulleys:
1 - tensioning device;
2 — a pulley of the pump of system of strengthening of a steering;
3 - generator;
4 - fan pulley;
5 - crankshaft pulley.
Please note that if necessary, you will have to remove other V-belts, or you will need to disconnect the front engine mount.
Finally, tighten the belts, drive about a hundred kilometers and then retension (V-belt tension, see earlier in this chapter).
The same section describes how the alternator poly V-belt is tensioned (since 9/91).
You will find out which V-belt where to put in the Audi-100 from the table on the previous page.
Replacing the poly V-belt on models with a 5-cylinder engine
Remove protective cover.
Disconnect the air duct from the air filter.
Remove the viscous fan, which requires a special tool (see chapter «Cooling system»).
Put the fan in rings (frame) at the radiator.
Unscrew the radiator frame and pull it up together with the fan.
Install the wrench on the tensioner and move it to the right.
Insert pin (e.g. a suitable bolt, etc.) into the hole provided for this and thus fix the tensioner.
Mark the direction of rotation of the belt with chalk or felt-tip pen.
Remove poly V-belt.
When installing with the V-ribbed belt applied, lift the tensioner with a wrench and remove the pin.
Follow the prescribed fan tightening torque (see chapter «Cooling system»).
Left: The V-ribbed belt tensioner in a 6-cylinder engine is secured with a star bolt, which is fitted with a star head for turning (2) with a suitable spanner. Pin (1; in the illustration, this role is played by a punch) is inserted into the hole provided for this on the tensioner, whereby the tensioner is fixed in this position.
Right: in the figure, the tensioner pulley is fixed with a hexagonal punch, which makes it possible to turn it with a ring wrench.
So the V-ribbed belt is put on various pulleys for models with a 6-cylinder engine without air conditioning.
The figure shows the passage of the polypin belt on a model with a 6-cylinder engine equipped with air conditioning.
Replacing the poly V-belt on models with a 6-cylinder engine
Remove poly V-belt cover.
Older version: Install a 15 mm ring wrench on the tensioner hexagon.
On newer versions: Remove the tensioner pulley cover and place a TORX wrench or 10mm Allen key inside the pulley on the central screw.
For everyone: Swivel tensioner to the right.
Fix the tensioner. To do this, insert the pin into the holes provided for this.
Mark the direction of rotation of the belt with chalk or felt-tip pen.
Remove poly V-belt.
When installing, place the V-ribbed belt first on the drive and guide rollers; lastly on the tension roller.
Raise the tensioner again with a wrench and remove the pin.
Install cover.
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