Remove poly V-belt.
Unscrew and remove the polypin belt tensioner.
Supercharged cars
Disconnect the hose from the connecting pipe.
Turning the crankshaft of the engine, in the direction of its working rotation, for the bolt securing the crankshaft pulley, 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 installing the piston of the first cylinder at TDC on the compression stroke, the large holes of the fixing plates on the camshaft pulleys must be directed towards each other (see fig. 2.45). Otherwise, turn the engine crankshaft one revolution.
Lock the crankshaft in this position. To fix the crankshaft from the cylinder block, unscrew the ignition timing sensor and screw in the AUDI-3242 set screw instead of the sensor (see fig. 2.46).
Unscrew the bolts and remove the lower casing of the toothed belt (see fig. 2.47).
Install special fixing AUDI-3391 (see fig. 2.50), holding the camshaft pulleys from turning. Loosen five turns alternately (but do not unscrew completely) camshaft pulley bolts. Remove the special retainer AUDI-3391.
In turn, remove both pulleys from the camshafts with a puller. 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.
Use an 8 mm Allen key to turn the tensioner 1 clockwise (pic. 2.48) toothed belt until the lever 2 is raised so that the holes in the piston and the tensioner housing 3 align, and insert a wire lock 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, unscrewing the pulley mounting bolt is not required.
Unscrew the poly V-belt guide roller.
Mark the direction of rotation of the toothed belt with a marker or paint and remove it.
Attention. When reinstalling the toothed belt, install it so that the arrow on the belt, marked before removing the belt, matches the direction of rotation of the engine pulleys. If, after installation, the toothed belt rotates in the opposite direction, cracks in the belt may occur and engine failure.
Install the timing belt over the engine pulleys, starting with the crankshaft pulley and ending with the idler pulley. When installing a previously removed belt, install it in accordance with the marked marks (see fig. 2.49).
Install special fixing AUDI-3391 (see fig. 2.50), holding the camshaft pulleys from turning when the toothed belt is tensioned.
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 camshaft pulley bolts to 55 Nm.
Remove the tool holding the camshaft pulleys.
Install the poly V-belt guide pulley and tighten the fastening bolt to 45 Nm.
Install the V-ribbed belt tensioner and tighten the fastening bolts to 55 Nm.
Unscrew the set screw 3242 holding the engine crankshaft from turning and screw in the screw plug instead, tightening it with a torque of 10 Nm.
Tighten the belt pulley bolts (vibration damper) torque 20 Nm.
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