Remove the V-ribbed belt and viscous fan clutch.
Set the piston of the third cylinder to TDC, for which, turn the crankshaft with the pulley mounting bolt in the direction of working rotation until the mark appears "FROM" (TDC) on the camshaft in the oil filler hole (see fig. 2.53).
Lock the crankshaft in this position. To fix the crankshaft from the cylinder block, unscrew the plug and screw in the AUDI-3242 set screw instead of the plug (see fig. 2.46).
Unscrew the cover covering the end of the camshaft on the right cylinder head (see fig. 2.54). When installing, a new cover must be used.
Replace the caps with the AUDI-3458 locking camshaft positions (see fig. 2.55). Instead of clamps, you can use a steel ruler 40 mm wide and 5 mm thick.
Remove vibration damper from fuel pump pulley (see fig. 2.56). Nut 2 (pic. 2.56) do not unscrew the fuel pump pulley fasteners. Otherwise, the injection timing of the fuel pump will change.
Remove bolts 1 (pic. 2.54) and remove the vacuum pump from the front side of the left cylinder head.
Loosen the tension of the fuel pump drive timing belt (see fig. 2.61). Remove the toothed belt. Before removal, use chalk, marker or paint to mark the direction of rotation of the toothed belt. If, when installing a previously used toothed belt, the toothed belt rotates in the opposite direction, this will lead to its destruction.
Unscrew the bolts and remove the vibration damper. When removing the vibration damper, unscrewing the pulley mounting bolt is not required.
Unscrew a bolt of fastening of the bottom casing of a gear belt (4, fig. 2.57).
Remove the viscous radiator fan pulley bolt.
Remove the bolts securing the viscous radiator fan bracket and idler pulleys (1-3, fig. 2.57).
Unscrew bolts of fastening of a pulley of a gear belt from a pulley of the fuel pump.
Alternately, using the special tool AUDI-3036 (see fig. 2.58) fix the camshaft pulley from turning and unscrew it five turns (but do not unscrew completely) camshaft pulley bolts.
Turn the toothed belt tensioner clockwise with an 8mm socket wrench and lock it in the retracted position with a 2mm diameter pin (see fig. 2.59).
Using a puller, remove both camshaft pulleys from the camshaft seating cones. When removing the pulleys, the puller must rest against the bolts of the camshaft pulleys. The camshaft pulleys must rotate freely, but not hang on the camshaft mounting cones.
Unscrew a bolt and remove a pulley of a gear belt together with a belt from the left head of the block of cylinders.
Install the timing belt first on the crankshaft pulley, then on the right camshaft pulley, idler pulley, idler pulley and water pump pulley.
Finally install the timing belt on the left camshaft pulley, install the pulley on the camshaft and fix it with the bolt (see fig. 2.60).
Release the toothed belt tensioner and remove the fixing pin, and the toothed belt is automatically tensioned. Using an 8 mm hexagon wrench, turn the tension roller to a tightening torque of 15 Nm in the direction of belt tension and then release the key, which ensures the correct belt tension.
Tighten the timing belt tensioner bolt to 45 Nm.
Alternately, using the special tool AUDI-3036 (see fig. 2.58) secure the camshaft pulley against turning and screw in the camshaft pulley mounting bolts, tightening them to a torque of 80 Nm.
Tighten the bolts for the viscous radiator fan bracket, idler pulley, and lower toothed belt guard (see fig. 2.57).
Fix the fuel pump pulley with pin AUDI-3359 (see fig. 2.61).
Install the fuel pump drive pulley so that the bolts 2 (pic. 2.61) located in the middle of the elongated pulley holes, and tighten the bolts just enough to turn the fuel pump drive pulley on the camshaft pulley.
Install the fuel pump timing belt.
Adjust the tension of the timing belt of the fuel pump, for which, with a hex wrench, turn the tension mechanism counterclockwise until the marks are aligned, and tighten the nut with a second wrench to a torque of 35 Nm (see fig. 2.61).
Tighten three bolts 2 (pic. 2.61) fastening the pulley with a torque of 20 Nm.
Unscrew the AUDI-3242 set screw that fixed the crankshaft and screw in the screw plug instead, tightening it with a torque of 10 Nm.
Remove the AUDI-3458 camshaft retainers.
Turn the crankshaft two turns, set it to the TDC position of the third cylinder on the compression stroke and check the installation of the crankshaft and camshafts. To check the position of the crankshaft from the cylinder block, unscrew the plug and screw in the AUDI-3242 set screw instead of the plug. To check the position of the camshafts, install the AUDI-3458 camshaft position clamps. If the AUDI-3242 set screw and AUDI-3458 clamps are installed, then the installation of the crankshaft and camshafts is normal.
Install the vibration damper on the fuel pump pulley, and fix it with bolts, tightening them to a torque of 20 Nm.
Install the vibration damper on the crankshaft pulley, while checking that the mark (see fig. 2.62) is aligned with the mark on the toothed belt pulley, and tighten the vibration damper mounting bolts to 25 Nm.
On the left cylinder head, install a vacuum pump and secure it with bolts, tightening them with a torque of 10 Nm.
Screw in a new cap covering the end of the camshaft on the right cylinder head (see fig. 2.54).
Install poly V-belt.
Check the injection timing of the fuel pump.
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