Warning: Incorrect installation of the toothed belt can cause very severe engine damage. If you lack experience, contact the workshop.
Withdrawal
1. Remove the lower casing of a motor compartment.
2. Remove poly V-belt.
3. Remove the V-ribbed belt tensioner. To do this, slowly loosen the tensioner and unscrew the hexagon bolt SW 10.
4. Unfasten and remove the toothed belt guard on both sides.
5. Set the crankshaft to the TDC position for cylinder 1. To do this, shift the gearbox to neutral gear, tighten the handbrake and turn the crankshaft clockwise by the central bolt of the belt pulley to the crankshaft until the mark on the belt pulley - B - does not stands against the setting mark - A. Here you need a strongly bent ring spanner or an interchangeable socket SW 24 (double hexagon).
6. At the same time, the large holes in the mounting plates of the camshaft gears must be located inward with respect to each other, otherwise turn the crankshaft one turn.
7. Lock the crankshaft in this position. To do this, unscrew the ignition timing sensor from the left side of the crankcase. The sensor is located on top of the crankcase at the height of the middle cylinder.
8. Instead of the sensor, screw in the AUDI-3242 rod and tighten it lightly. At the same time, the rod enters the hole on the counterweight of the crankshaft and stops it. Before screwing in the rod, check if the hole is visible or tangible.
9. Remove the 8 hex socket head bolts of the vibration damper (V-belt pulley on crankshaft).
Warning: Do not loosen the center bolt.
10. Remove the bottom casing of a gear belt.
11. Bolt of fastening of a tension roller of a gear belt - 1 - release by means of an 8 mm key with external hexagon. With the same wrench, turn the tension roller to the right in the direction of the arrow, due to which the tension of the toothed belt is weakened.
2.8L engine (30 valves)
Location of the main systems of the 6-cylinder engine 2.6 / 2.8 l
- 1. Vacuum pump
- 2. Hydraulic pusher
- 3. CO suction tube
- 4. Exhaust valve
- 5. Piston
- 6. Starter
- 7. Oil pump
- 8. Generator
- 9. Spark plug
- 10. Valve nozzle
- 11. Dual ignition coils (3 pieces)
- 12. Toothed belt
- 13. V-ribbed belt
- 14. Oil filter
Withdrawal
1. Turn the tension roller evenly to the right until the tension lever - 2 - sinks the tension rod so far that a 2 mm rod, such as a drill or a spring cotter pin, can be inserted. Insert the rod, and thereby the tension roller will be locked.
Warning: If a used belt is being used again, be sure to mark the direction of its movement with an arrow using a felt-tip pen or marker. Installing the toothed belt in the reverse direction of travel can cause it to break and severely damage the engine. Therefore, always install the belt so that the arrow printed on it points in the direction of rotation of the engine (clockwise when viewed from the front).
2. Loosen the poly V-belt guide roller.
3. Remove the timing belt cover from the crankshaft.
4. Remove the toothed belt.
Warning: The toothed belt must not be bent.
5. A kinked belt must always be replaced, as it can break during subsequent use, causing severe engine damage. If possible, do not change the position of the gears.
Installation
1. Loosen the camshaft gears on the left and right by about 3 turns, do not unscrew the bolts.
2. Slide the camshaft gears on the left and right from the cones using a puller. The grips of the puller must be wound behind the rear end of the hub.
Warning: The gears must be displaced from the cones so that they are movable on the camshafts, but do not wobble.
3. Place the toothed belt on both camshaft gears, then on the idler roller and crankshaft gear, and finally on the tension roller.
4. Install retainer AUDI-3243 (for an engine with a displacement of 2.8 liters (30 valves): AUDI-3391).
Engines with two valves per cylinder (up to 174 l. With.)
Order of execution
1. Using an Allen key SW 8, tighten the tensioning roller mounting bolt so that the roller on the eccentric can still be easily turned by hand.
2. Turn the tensioning roller to the right with an Allen key SW 8 and hold. Due to this, the toothed belt is tensioned.
3. Tighten the toothed belt tensioning roller bolt using a second hexagon wrench SW 8.
4. Check toothed belt tension. To do this, take the toothed belt with your thumb and forefinger in the middle between the camshaft gear and the coolant pump and twist. The toothed belt should only allow 90 degrees of twisting.
5. Otherwise, loosen the tension roller mounting bolt and tighten the tension roller accordingly until the required belt tension is reached.
6. Turn the crankshaft of the engine by hand one turn in the direction of rotation and repeat the check of the belt tension, tighten the belt if necessary.
7. Tighten the tension roller mounting bolt to 45 Nm.
Engines with five valves per cylinder (with a working volume of 2.8 l (30 valves), 193 l. With.)
Order of execution
1. Using an Allen key SW 8, turn the tensioning roller to the right until the locking pin can be removed from the tensioning element. Pull out the pin.
2. Using a torque wrench with an external hexagon SW 8, tighten the toothed belt tensioner pulley to a torque of 15 Nm. Tighten the tension roller mounting bolt to 20 Nm.
3. Screw the poly V-belt guide roller with a torque of 45 Nm.
4. Tighten the camshaft gears to a torque of 70 Nm (for an engine with a working volume of 2.8 liters (30 valves) – 55 Nm). Loosen the camshaft retainer.
5. Unscrew the crankshaft fixing pin.
6. Wrap the ignition moment sensor with a torque of 10 Nm.
7. Establish the lower casing of a gear belt.
8. Insert the vibration damper so that the protrusion on the crankshaft gear wheel fits into the groove of the vibration damper. Using an 8 mm hexagon socket wrench, tighten the vibration damper to a torque of 25 Nm.
9. Install the left and right toothed belt guards.
10. Set the V-ribbed belt tensioner so that the locking pin enters the hole in the cylinder block. Tighten the hexagon socket bolt to 45 Nm.
11. Attach the toothed belt guards on both sides.
12. Install poly V-belt.
13. Install the lower engine compartment cover.
14. Lower the car.
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