Remove the poly V-belt.
Unscrew and remove the poly-pin belt tensioner mechanism.
Supercharged cars
Disconnect the hose from the connecting pipe.
Turning the engine crankshaft in the direction of its working rotation, using the crankshaft pulley mounting bolt, set the piston of the first cylinder to TDC. Check that the mark on the crankshaft pulley is aligned with the pointer on the casing (see fig. 2.44).
Check the position of the camshaft timing belt pulleys. When the piston of the first cylinder is set to TDC in the compression stroke, the large holes of the locking plates on the camshaft pulleys should be directed towards each other (see fig. 2.45). Otherwise, turn the engine crankshaft one revolution.
Fix the crankshaft in this position. To fix the crankshaft from the cylinder block, unscrew the ignition timing sensor and screw in the AUDI-3242 installation screw instead of the sensor (see fig. 2.46).
Unscrew the bolts and remove the lower timing belt cover (see fig. 2.47).
Install special retainer AUDI-3391 (see fig. 2.50), holding the camshaft pulleys from turning. Unscrew them five turns in turn (but don't unscrew it completely) camshaft pulley mounting bolts. Remove special lock AUDI-3391.
Use a puller to remove both pulleys from the camshaft seat cones in turn. When removing the pulleys, the puller should rest against the camshaft pulley mounting bolts. The camshaft pulleys should rotate freely, but not dangle on the camshaft seat cones.
Using an 8 mm Allen key, turn the tensioning mechanism 1 (Fig. 2.48) of the toothed belt clockwise until the lever 2 rises so much that the holes in the piston and housing 3 of the tensioning mechanism are aligned, and insert a wire retainer or a 2.0 mm drill shank into the holes.
Unscrew the bolts and remove the belt pulley (vibration damper). When removing the belt pulley, it is not necessary to unscrew the pulley mounting bolt.
Unscrew the poly V-belt guide roller.
Use a marker or paint to mark the direction of rotation of the timing belt and remove it.
Caution: When reinstalling the timing belt, install it so that the arrow on the belt, which was applied before removing the belt, matches the direction of rotation of the engine pulleys. If the timing belt rotates in the opposite direction after installation, cracks may occur in the belt and the engine may break down.
Install the toothed belt on the engine pulleys, starting with the crankshaft pulley and ending with the tension roller. When installing the previously removed belt, install it in accordance with the marks applied (see fig. 2.49).
Install special retainer AUDI-3391 (see fig. 2.50), holding the camshaft pulleys from turning when the timing belt is tensioned.
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 camshaft pulley mounting bolts to 55 Nm.
Remove the camshaft pulley retaining device.
Install the poly V-belt guide roller and tighten the mounting bolt to a torque of 45 Nm.
Install the poly V-belt tensioner mechanism and tighten the mounting bolts to a torque of 55 Nm.
Unscrew the set screw 3242, which holds the engine crankshaft from turning, and screw in the threaded plug instead, tightening it to a torque of 10 Nm.
Tighten the belt pulley mounting bolts (vibration damper) torque of 20 Nm.
The article was copied from the website AudiManual