Remove the poly V-belt and the radiator fan viscous coupling.
Set the piston of the third cylinder to TDC, for which turn the crankshaft in the direction of working rotation using the pulley mounting bolt until the "OT" (TDC) mark appears on the camshaft in the oil filler neck hole (see fig. 2.53).
Fix 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). A new cover must be used during installation.
Install AUDI-3458 camshaft position locks instead of the covers (see fig. 2.55). Instead of clamps, you can use a steel ruler 40 mm wide and 5 mm thick.
Remove the vibration damper from the fuel pump pulley (see fig. 2.56). Do not unscrew nut 2 (Fig. 2.56) securing the fuel pump pulley. Otherwise, the fuel pump injection moment will change.
Unscrew bolts 1 (Fig. 2.54) and remove the vacuum pump from the front side of the left cylinder head.
Loosen the fuel pump drive timing belt tension (see fig. 2.61). Remove the timing belt. Before removing, use chalk, marker or paint to mark the direction of rotation of the timing belt. If the timing belt rotates in the opposite direction when installing a previously used timing belt, it will cause its destruction.
Unscrew the bolts and remove the vibration damper. When removing the vibration damper, it is not necessary to unscrew the pulley mounting bolt.
Unscrew the lower timing belt cover mounting bolt (4, Fig. 2.57).
Remove the viscous coupling radiator fan pulley bolt.
Remove the bolts securing the viscous clutch radiator fan bracket and the idler pulleys (1-3, Fig. 2.57).
Remove the timing belt pulley mounting bolts from the fuel pump pulley.
Alternately, using a special device AUDI-3036 (see fig. 2.58) secure the camshaft pulley from turning and unscrew it five turns (but don't unscrew it completely) camshaft pulley mounting bolts.
Using an 8mm socket wrench, turn the timing belt tension roller clockwise and secure it in the retracted position with a 2mm pin (see fig. 2.59).
Using a puller, remove both camshaft pulleys from the camshaft seat cones. When removing the pulleys, the puller should rest against the camshaft pulley mounting bolts. The camshaft pulleys should rotate freely, but not wobble on the camshaft seat cones.
Unscrew the bolt and remove the timing belt pulley together with the belt from the left cylinder head.
First install the timing belt on the crankshaft pulley, then the right camshaft pulley, tensioner pulley, idler pulley and water pump pulley.
Finally install the timing belt on the left camshaft pulley, install the pulley on the camshaft and secure it with the bolt (see fig. 2.60).
Release the timing belt tensioner and remove the locking pin, the timing belt will be tensioned automatically. Use an 8mm Allen key to turn the tension roller in the direction of belt tension until the tightening torque is 15Nm, and then release the key, which ensures the correct belt tension.
Tighten the timing belt tensioner mounting bolt to 45 Nm.
Alternately, using a special device AUDI-3036 (see fig. 2.58) secure the camshaft pulley from turning and tighten the camshaft pulley mounting bolts to a torque of 80 Nm.
Tighten the viscous clutch radiator fan bracket, idler pulley and lower timing belt cover mounting bolts (see fig. 2.57).
Secure the fuel pump pulley with the AUDI-3359 pin (see fig. 2.61).
Install the fuel pump drive pulley so that bolts 2 (Fig. 2.61) are located in the middle of the elongated holes in the pulley, and tighten the bolts enough to allow the fuel pump drive pulley to rotate on the camshaft pulley.
Install the fuel pump timing belt.
Adjust the tension of the fuel pump toothed belt by using a hex key to turn the tensioning mechanism counterclockwise until the marks align, and using a second key to tighten the nut to a torque of 35 Nm (see fig. 2.61).
Tighten the three bolts 2 (Fig. 2.61) securing the pulley to a torque of 20 Nm.
Unscrew the AUDI-3242 set screw that fixed the crankshaft and screw in the threaded plug instead, tightening it to a torque of 10 Nm.
Remove the AUDI-3458 camshaft retainers.
Turn the crankshaft two revolutions, set it to the TDC position of the third cylinder in the compression stroke and check the installation of the crankshaft and camshafts. To check the position of the crankshaft, unscrew the plug from the cylinder block and screw in the AUDI-3242 setting screw instead of the plug. To check the position of the camshafts, install the AUDI-3458 locking pins that fix the positions of the camshafts. If the AUDI-3242 setting screw and the AUDI-3458 locking pins are installed, then the installation of the crankshaft and camshafts is normal.
Install the vibration damper on the fuel pump pulley and secure it with bolts, tightening them to a torque of 20 Nm.
Install the vibration damper on the crankshaft pulley, making sure that the mark (see fig. 2.62) align with the mark on the timing belt pulley and tighten the vibration damper mounting bolts to 25 Nm.
Install the vacuum pump on the left cylinder head and secure it with bolts, tightening them to a torque of 10 Nm.
Screw in a new cover that covers the end of the camshaft on the right cylinder head (see fig. 2.54).
Install the poly V-belt.
Check the fuel pump injection timing.
(This article was copied from an online resource Audimanual.ru)