Four-cylinder petrol engines 1.6, 1.8 l.
Gear drive elements. 1.6L engine shown
- 1 bolt, 45 Nm
- 2 engine holder
- 3 bolt, 25 Nm
- 4 holder
- 5 Timing belt top cover
- 6 middle toothed belt cover
- 7 nut, 20 Nm
- 8 puck
- 9 tension roller
- 10 toothed belt
Check for wear. Before removing, mark the direction of rotation with an arrow. Do not bend the toothed belt.
- 11 toothed belt rear cover
- 12 O-ring. Be sure to replace.
- 13 coolant pump
- 14 bolt, 15 Nm
- 15 gear crankshaft
- 16 bolt, 90 Nm + 1/4 turn
Be sure to replace. The thread and shoulder must not be lubricated. Tighten the bolt to 90 Nm and then tighten 1/4 turn with a hard wrench (90 °). Attention: Turning can be done in several steps.
- 17 toothed belt lower cover
- 18 bolt, 10 Nm
- 19 power steering pump pulley
- 20 V-belt
Before removing, mark the direction of rotation.
- 21 crankshaft/vibration damper pulley
Installation is only possible in one position. The holes are appropriately offset.
- 22 V-belt tensioner.
Tilt with a wrench to loosen the V-belt.
Timing belt drive elements. Petrol engine 1.8 l / 125 hp
- 1 bolt, 45 Nm
- 2 engine support
- 3 Timing belt top cover
- 4 bolt, 100 Nm
For loosening and tightening, use the Audi holding tool 3036
- 5 camshaft pulley
Operating position: TDC marking visible.
- 6 bolt, 45 Nm
- 7 tension roller
- 8 puck
- 9 toothed belt
Check for wear. Before removing, mark the direction of rotation. Do not bend the belt.
- 10 coolant pump
- 11 O-ring
- 12 bolt, 15 Nm
- 13 toothed belt tensioner
- 14 crankshaft timing belt pulley
Installation is only possible in one direction. The holes are offset accordingly.
- 15 bolt, 90 Nm + 1/4 turn. Be sure to replace. Lubricate the thread and collar with oil. Use the Audi 3099 holding tool to loosen and tighten. When installing the holding tool, place two washers between the tool and the pulley. Tighten the bolt to 90 Nm and then tighten with a hard wrench 1/4 turn (90°). Attention: Turning can be done in several steps.
- 16 middle toothed belt cover
- 17 bolt, 10 Nm
- 18 ribbed V-belt
- 19 crankshaft pulley/vibration damper
Installation is only possible in one direction. The holes are offset accordingly.
- 20 bolt, 25 Nm
- 21 toothed belt lower cover
The engines are equipped with an automatically operating tension roller in the toothed belt drive, which keeps the belt tension always constant. This increases the service life and reduces the noise level of the toothed belt.
Withdrawal
1. Remove the V-belt, while referring to subsection Removing and installing ribbed V-belt.
2. Loosen the V-belt tensioner.
3. Set the crankshaft to the TDC position of the end of the compression stroke of the piston of the first cylinder, while referring to subsection Setting the piston of the first cylinder to TDC.
4. Since the right engine support is disconnected, the engine must be hung on the AUDI-10-222A and 10-222A/1 fixture. The device must be installed on the wing mount and secured with hooks to the engine lugs.
Warning: If this tool is not available, run a wood-studded garage hoist under the oil pan and lift the engine slightly.
5. Loosen the 4 socket head screws and remove the pulley (vibration damper) from the crankshaft. The engine is kept from turning by the central bolt.
6. Turn away bolts and remove the bottom and top covers of a gear belt.
7. Loosen the bolts and remove the coolant expansion tank and power steering reservoir (indicated by arrows) and lay aside with distribution lines.
8. Remove the bolts and disconnect the right engine mount from the body and from the engine holder (indicated by arrows).
9. Turn away bolts and remove the right holder of the engine from the engine (indicated by arrows).
Warning: To remove the front bolt, the engine must be slightly lifted with a tool.
10. Engines 1.6 l: Turn away nuts of fastening of a tension roller of a toothed belt.
Engine 1.8 l
11. Screw in the hairpin -1 - M5x55 in the toothed belt tensioner.
12. Screw nut -2- with large washer -3- onto stud -1-.
The tensioner stem should be tensioned until the holes in the stem and body match up, allowing the insertion of a 1.5 mm rod, drill or cotter pin (arrow on accompanying illustration). Now the stem is fixed and the toothed belt is unloaded.
All engines
13. Remove the toothed belt.
Warning: After removing the toothed belt, do not change the position of the camshaft and crankshaft. If it is necessary to rotate the camshaft with the toothed belt removed, make sure that the crankshaft is not at TDC. Otherwise, there is a risk of damage to the valves and the piston head. To do this, mark the position of the crankshaft pulley by marking the crankshaft pulley and cylinder block with paint. Then turn the crankshaft pulley forward or backward 1/4 turn (90°).
Installation
1. When tensioning the toothed belt, the engine must be cold.
2. Slide the toothed belt over the crankshaft and water pump gears.
Warning: If an old belt is being installed, be sure to observe the direction of rotation. Replacing the belt in a different position can cause it to break and, as a result, damage the engine. Therefore, be sure to install timing belts so that the arrow marked when removing the belt points in the direction of engine rotation. The engine, viewed from the right side of the vehicle, rotates clockwise.
3. Make sure the markings on the crankshaft and camshaft wheels align with the TDC markings. The engine is at the same time in the TDC position of the piston of the first cylinder.
4. Reinstall the lower toothed belt cover and secure it.
5. Secure the crankshaft pulley with a torque of 25 Nm. Note: The pulley can only be installed in one position. Check that it is fixed.
6. Put the toothed belt on the tension roller and the camshaft wheel.
Engine 1.6 l
7. Check the position of the tension roller: retainer (arrow on accompanying illustration) must fit into the groove in the cylinder head. Otherwise, turn the holder.
8. Turn the tension roller by the eccentric with a screwdriver, e.g. HAZET 2587 to the left (arrow direction) so that the notch -1- and the pointer -2- are opposite. For control, you can use a mirror if necessary. In this position, tighten the nut to 20 Nm.
9. Rotate the engine 2 revolutions in the direction of rotation and stop again at the TDC position of the camshaft marking. It is important that the last 45°be turned without stopping.
10. Check the position of the serif -1- and the pointer -2-, they should be opposite each other. Otherwise, install the tension roller again.
Engine 1.8 l
11. Take out the locking rod (arrow on accompanying illustration) and unscrew the grub screw -1-. The rod at the pressure element monitors the correct tension of the toothed belt.
All engines
12. Turn the engine over twice and check the TDC position of the camshaft and crankshaft. All markings must match when the toothed belt is tensioned. Otherwise, remove the toothed belt again and repeat the adjustment.
13. Install the top timing belt cover.
14. Secure the right engine holder with a torque of 45 Nm.
15. Fix the right support of the engine on a body and the holder of the engine with new bolts the moments presented in Specifications. In this case, first tighten all the bolts with a torque wrench, and then tighten with a hard wrench at an angle of 90° (1/4 turn).
Warning: Bolts will be stretched when tightened. Therefore, after each tightening, new bolts should be used.
16. The bolts, when tightened, receive a residual hood. Therefore, after each tightening, new bolts should be used.
17. Fasten the V-belt tensioner with a torque of 20 Nm.
18. Install the V-belt, while referring to subsection Removing and installing ribbed V-belt.
19. Install the coolant expansion tank and power steering fluid reservoir.
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