Belt drive units with a four-cylinder engine with the front of the car removed
- 1 - air conditioner compressor;
- 2 - tension roller;
- 3 - belt pulley of the crankshaft;
- 4 - tension roller;
- 5 - generator;
- 6 - viscous fan hub;
- 7 - belt pulley of the servo pump;
- 8 - intermediate roller.
To dismantle the V-belt (2) water pump, it is necessary to unscrew the pulley (1) water pump.
Neither the figure nor the photograph is the same topic: the tension of the V-ribbed belt in a six-cylinder engine. In the illustration, the tensioner pulley is secured with a hexagon head bolt and can be swiveled out with a spanner wrench. The photo shows a TORX bolt, on which a TORX nozzle is put on to tilt the roller (2) with a suitable spanner. Pin (1; here is a punch) is inserted into the hole provided for this purpose in the tensioning device, due to which the tensioning device is fixed in this position.
Audi provides preventive replacement of the V-ribbed belt of the six-cylinder engine and the small V-belt of the water pump of the four-cylinder engine every 120,000 km. The large belt of the six-cylinder engine, being the drive of many auxiliary units, is subjected to more stress, the V-belt of the four-cylinder engine is the drive of the water pump, which is critical to the life of the engine (see text below).
Removing the V-belt and V-ribbed belt from a four-cylinder engine
Dismantling is described here (replacement) all drive belts. Therefore, this description can be used for other cases. The disassembly sequence refers to the dismantling of all belts, but is not necessary when replacing one belt.
After 120,000 km, Audi requires only a short V-belt to be replaced, but due to the amount of work, all belts are suggested to be replaced.
1. First of all, unscrew the front of the car and bring it to the service position (chapter Body parts).
2. Mark the direction of rotation of the V-ribbed belt with chalk or felt-tip pen (for mounting).
3. V-ribbed belt for air conditioner compressor: Loosen both fastening bolts of the belt tensioner
4. This releases the tension on the V-ribbed belt and can be removed
5. V-ribbed belt for servo pump, alternator and viscous fan: fit the open end wrench on the tensioner and fold it to the right.
6. Lock the tensioner. To do this, insert a pin (e.g. a suitable drill) into the hole provided for this.
7. Remove the V-ribbed belt between the servo pump and the generator from the generator side.
8. Raise the tensioner again with the wrench and remove the pin.
9. Block the viscous fan belt pulley with a M5 x 60 mm bolt and unscrew the fixing bolt (internal hexagon 8 mm at the back).
10. Remove the viscous fan and ribbed belt.
11. Water pump V-belt: Loosen the three belt pulley bolts on the water pump. To do this, block the belt pulley of the servo pump with a pin.
12. Remove the belt pulley and belt.
13. See next section for mounting and tensioning belts.
Tip: A new V-belt must never be pulled over the belt pulleys with a screwdriver, as the resulting breaks would pre-program the next defect in the belt.
Mounting the V-belt and V-ribbed belt on a four-cylinder engine
1. When installing a used V-ribbed belt, observe the previously marked direction of rotation.
2. Water pump V-belt: Tighten the water pump pulley bolts in several steps with the V-belt applied. At the same time, turn the belt pulley constantly so that the V-belt does not get caught between the halves of the belt pulleys.
3. Only when the V-belt is running from the outside in the correct position, tighten the bolts to 25 Nm.
4. V-ribbed belt for air conditioner compressor: The fastening bolts of the tensioning roller are still loose.
5. Check if the tension roller console moves easily.
6. Install a torque wrench on the hexagon of the idler roller console and tighten to 25 Nm - the belt tension will be correct.
7. Tighten the mounting bolts (20 nm).
8. V-ribbed belt for servo pump, alternator and viscous fan: fit an open end wrench on the tensioner and fold it to the right.
9. Lock the tensioner.
10. Apply poly V-belt; make sure that the belt fits correctly on the belt pulleys.
11. With the V-ribbed belt applied, raise the tensioner again with a wrench and remove the pin.
12. Tightening torque for viscous fan: 45 Nm.
Dismantling and installation of the V-ribbed belt from a six-cylinder engine
1. Remove the engine cover (chapter Engines).
2. Remove the V-ribbed belt cover.
3. Vehicles with viscous fan: remove the viscous fan (chapter Cooling system).
4. Install the SW 17 wrench on the hexagon of the tension roller.
5. On vehicles without a hexagon: wring out the cover of the tension roller and install a TORX-T40 wrench on the central bolt of the tension roller.
6. Tilt tensioner to the right.
7. Lock the tensioner. To do this, insert a pin (e.g. a suitable drill) into the hole provided for this.
8. Mark the direction of rotation on the belt with chalk or felt-tip pen.
9. Remove poly V-belt.
10. When installing: first put the V-ribbed belt on the crankshaft pulley and idler pulley, then on the tension roller.
11. Raise the tensioner again with the wrench and remove the pin.
12. Install covers.
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