Table of contents: Removal and installation the… ↓ Removal the timing belt from the… ↓ Removal and installation, tensioning… ↓
1. Timing belt installation details are shown in the illustration 10.1. The exception is the upper cover (4) of the timing belt, which has a slightly different shape and is secured at the top not with bolts (5), but with clamps.
Removal and installation the tensioner
2. Set the radiator frame to the service position (see Section 30).
3. Release the fasteners and remove the top engine cover by moving it upwards (see illustration 29.9).
4. Remove the alternator drive belt (see Section 7).
5. Remove the bolts (1 in illustration 7.1) and remove the alternator belt tensioner. Remove the upper timing belt cover from the retainers.
6. Follow the steps described in paragraphs 7-10 Section 10.
7. Installation is performed in the reverse order of dismantling the components. Please note the following information.
8. After installing the tensioner, loosen the clamp that prevents it from falling, loosen the nut (1 in illustration 10.12) and tension the timing belt as described in paragraphs 31-36 Section 10.
9. The tightening forces for the fasteners are indicated in the captions to the illustration 10.1. Apply thread sealant to the threads of the timing belt center cover mounting bolts before tightening them.
Removal the timing belt from the camshaft gear
10. Set the radiator frame to the service position (see Section 30).
11. Release the fasteners and remove the top engine cover by moving it upwards (see illustration 29.9).
12. Remove the alternator drive belt (see Section 7).
13. Remove the upper timing belt cover from the clips.
14. Turn the crankshaft by the bolt of its gear wheel clockwise so that the piston of the first cylinder is at the TDC of the end of the compression stroke. In this case, the marks on the gear wheels of the crankshaft and camshafts should be opposite the TDC marks (see illustration 10.15).
15. Press the timing belt tensioner with a hex key with a uniform, light force in the direction of the arrow (see illustration 10.9) until it is possible to secure the tensioner piston using the T10008 insert plate. Insert this plate.
Note: The timing belt tensioner is coated with oil vapor and should be compressed slowly and evenly. Too much compression force may damage the tensioner.
16. To loosen the timing belt, loosen the nut (1 in illustration 10.12) tension roller and turn the eccentric with key No.3387 in the direction of the arrow. Remove the timing belt from the camshaft gear.
Note: The thrust projection (A) of the eccentric must not be bent.
Caution: When turning the camshaft with the timing belt removed, none of the pistons should be at TDC.
17. After finishing the work, align the marks on the gears with the timing marks (see illustration 10.15) and make sure that the tensioner is fixed with plate No. T10008. Put on the timing belt in the following sequence: water pump → tension roller → camshaft gear. Tension the timing belt as specified in paragraphs 31-36 Section 10.
18. Installation is performed in the reverse order of component dismantling. The tightening forces for the fasteners are indicated in the captions to the illustration 10.1.
Removal and installation, tensioning of the timing belt
19. Follow the steps described in paragraphs 2-5.
20. Turn the crankshaft by the bolt of its gear wheel clockwise so that the piston of the first cylinder is at the TDC of the end of the compression stroke. In this case, the marks on the gear wheels of the crankshaft and camshafts should be opposite the TDC marks (see illustration 10.15).
21. Holding the crankshaft from turning by the central bolt, unscrew the bolts (16 in illustration 7.1) fastenings of the crankshaft pulley and remove it.
22. Remove the middle and lower timing belt guards (see illustration 10.7).
23. Press the timing belt tensioner with a hex key with a uniform, slight force in the direction of the arrow (see illustration 10.9) until it is possible to secure the tensioner piston using the T10008 insert plate. Insert this plate.
Note: The timing belt tensioner is coated with oil vapor and should be compressed slowly and evenly. Too much compression force may damage the tensioner.
24. To loosen the timing belt, loosen the nut (1 in illustration 10.12) tension roller and turn the eccentric with key No.3387 in the direction of the arrow.
Note: The thrust projection (A) of the eccentric must not be bent.
25. If the belt being removed is intended to be reused, mark the direction of rotation on it with chalk or a felt-tip pen. Remove the timing belt.
Caution: When turning the camshaft with the timing belt removed, none of the pistons should be at TDC.
26. Place the timing belt on the crankshaft gear, taking into account the direction of the belt run (if a previously used belt is being installed).
27. Install the lower timing belt cover.
28. Install the crankshaft pulley onto the toothed wheel.
29. Align the marks on the gears with the timing marks (see illustration 10.15). Make sure that the tensioner is fixed with plate No. T10008 and put on the timing belt in the following sequence: water pump → tension roller → camshaft gear. Tension the timing belt as described in paragraphs 31-36 Section 10.
30. Further installation is carried out in the reverse order of dismantling the components. The tightening forces for the fasteners are indicated in the captions to the illustration 10.1. Use new crankshaft pulley mounting bolts. Apply thread sealant to the threads of the lower and middle timing belt cover mounting bolts.
This article was copied from an online resource: AudiManual.ru