Removal and installation a toothed belt with a hydraulically damped tension roller (Audi A2)

Table of contents: Removal ↓ Installation (valve timing… ↓ Checking the valve timing ↓ Installation ↓

Removal

Remove the right front wheel. Remove the sound insulation. Remove the poly V-belt. Remove the hood. If available, unfasten the bracket. Remove the engine cover "arrows". Remove the sound insulation underneath.

Lift the caps "3 and 4" of both parts of the windshield wiper arm with a screwdriver. Loosen the nuts of both parts of the windshield wiper arm with a few turns. Loosen the arms "1 and 2" of the windshield wipers on the axles one by one with light rocking movements. Completely unscrew the nuts and remove both parts of the windshield wiper arm. If it is not possible to remove the arm in this way, then in this case it is necessary to use a standard puller.

Disconnect the washer fluid supply pipe "3". If present, disconnect the plug connectors "4 and 5" of the heated windshield washer sprayers. Loosen the hose clamp "6" using hose clamps "V.A.G 1921" and remove the drain hose from the deflector grille. Remove the rubber seal "1" of the deflector grille. Remove the deflector grille "2". Unfasten the washer fluid supply pipe.

Loosen the nuts and bolts of the "arrow". Pull the fresh air supply duct forward and remove it, turning it to the right side of the car.

Remove the air duct hose "1" from the suction pipe, to do this, release the clamps (where available) "2" "arrow".

Vehicles with the letter designation AMF, VNS

Remove the resonator from the air guide pipe "arrow".

All cars

Disconnect plug connector "2" of air flow meter "G70". Remove vacuum hose "1". Loosen hose clamp "4" and remove air guide pipe together with air flow meter "G70". Ignore item "3".

Unscrew the poly V-belt tensioner "arrows".

Remove the upper part of the belt guard "arrows".

Loosen the torsional vibration damper by using a ring spanner on the central bolt.

Unscrew the central and lower parts of the belt protective cover "arrows".

Unscrew the lower bolt "1" of the engine support. Bolts "2 and 3" are unscrewed later.

Install the crossmember "10.222 A" with adapters "10.222 A/13" and adapter "T40093/6" on the edges of the bolted joints of the wings.

Caution! Insert the adapter "10. 222 A/13" into the hood catches "arrow".

The clamping bolt in the adapter "T40093/6" must be unscrewed. The adapter "T40093/6" is installed so that its bracket faces upward. Hook the hook of the lead screw carabiner "10.222 A/11" to the engine eye. Tighten the engine with the lead screw without lifting it.

Car with engine mount cover

Remove the engine mount cover by unscrewing bolts "1 and 2".

Unscrew bolts "1 and 3" and remove the bracket with engine mount "2".

Cars without engine mount cover

Nut "3" can only be loosened to replace the engine mount.

Unscrew bolts "1 and 2" and remove the bracket with the engine mount.

All cars

Unscrew the upper bolts "2 and 3" and remove the engine support. Ignore pos. "1".

Caution! The engine may only be turned by the crankshaft in the direction of its rotation…

Caution! The engine may only be turned by the crankshaft in the direction of its rotation (clockwise). To rotate the engine shaft, install the center bolt on the crankshaft.

Set the crankshaft to the "TDC" mark. The gap between both teeth of the camshaft sprocket should be opposite the marking 37. of the rear part of the protective belt cover "arrows". Fix the camshaft bushing with the "3359" lock. Fix the crankshaft sprocket with the "T10G50" crankshaft stopper.

Instructions: The crankshaft stopper can only be pushed onto the sprocket teeth from the outside.

The markings on the sprocket and crankshaft stopper "T10050" must be opposite each other. The journal of the crankshaft stopper "T10050" must enter the hole in the sealing flange. Mark the direction of rotation of the toothed belt with chalk or a felt-tip pen. Loosen the bolts "arrows" of the camshaft sprocket.

Insert the Allen key into the recess until it stops and turn the tension roller counterclockwise "arrow" until the timing belt tensioner can be fixed with the "T10008" locking plate.

Instructions: To avoid damage, insert the Allen key until it stops. The timing belt tensioner is damped with oil and compresses slowly when a uniform force is applied.

Loosen the tension roller mounting nut.

Unscrew the "arrow" bolts and remove the toothed belt tensioner. Remove the toothed belt.

Installation (valve timing adjustment)

The camshaft is fixed with the locking pin "3359". The crankshaft is fixed with the crankshaft stopper "T10050". The tension roller is fixed with the locking plate "T10008".

Instructions. Work on adjusting the toothed belt should be tangibly carried out only when the…

Instructions. Work on adjusting the toothed belt should be tangibly carried out only when the engine is cold. When turning the camshaft, none of the crankshaft pistons should be at "TDC". Risk of damage to valves/piston crown.

Screw in the "arrow" bolts not all the way. The camshaft sprocket should be able to be turned by hand, but should not turn on its own. Turn the camshaft sprocket clockwise within its extended holes until it stops. Install the toothed belt on the camshaft sprocket, tension roller, crankshaft sprocket, and then on the coolant pump sprocket.

Install the belt tensioner. Adjust the belt tensioner position as follows: turn the eccentric with the trunnion key "3387" counterclockwise "arrow" until it stops "A". Remove the locking plate "T10008".

To avoid cuts, wrap the tip and cutting edges of the 4.0 mm drill bit with insulating tape. Slowly turn the tensioner clockwise "arrow" until the shank of the 4.0 mm drill bit "pos. 2" can easily pass between the tension lever and the tensioner body. Gap "a" = 4.0±1.0 mm.

Instructions. The gap "a" decreases when tightening the tension roller nut, so it should be set slightly larger. The gap "a" decreases when the engine is warm.

Fix the tension roller in this position and tighten the tension roller nut to a torque of 20 Nm + 45°. Tighten the camshaft sprocket "arrow" bolts first to a torque of 25 Nm. Remove the lock "3359" and the crankshaft stopper "T10050".

Caution! The engine may only be turned by the crankshaft in the direction of its rotation (clockwise).

Turn the crankshaft 2 revolutions in the direction of rotation so that it is again in front of the "TDC" mark.

Check the gap value "a" between the tension lever and the tensioner housing again. Gap "a" = 4.0±1.0 mm. If the gap "a" does not correspond to the specified value, tension the tension roller as follows: holding the tension roller with the trunnion key "3387", loosen the nut "1" and turn the tensioning device until the specified gap value "a" is obtained. Fix the tension roller in this position and tighten the tension roller nut to a torque of 20 Nm + 45°.

Checking the valve timing

To check, fix the crankshaft sprocket once again with the crankshaft stopper "T10050". The markings on the sprocket and the crankshaft stopper "T10050" must be opposite each other. In this case, the journal of the crankshaft stopper "T10050" must enter the hole in the sealing flange. The journal of the crankshaft stopper "T10050" must enter the hole in the sealing flange using a rotational motion.

Instructions. If the crankshaft has passed the "TDC" mark, turn the crankshaft 1/4 turn back to re-align it with the engine rotation direction to the "TDC" mark. It is not allowed to turn the shaft in the opposite direction of engine rotation to adjust the installation of the crankshaft stopper "T10050". Check the possibility of fixing the camshaft bushing "3359" with the lock.

If the bushing can be fixed: loosen the camshaft sprocket "arrow" bolts. Put a spanner on the central camshaft bolt. Turn the bushing so that the "3359" lock can be inserted. Finally tighten the camshaft sprocket "arrow" bolts with a torque of 20 Nm + 45° (1/8 turn). Remove the crankshaft retainer and stopper.

Caution! The engine may only be turned by the crankshaft in the direction of its rotation (clockwise).

Turn the crankshaft 2 revolutions in the direction of rotation so that it is again in front of the "TDC" mark. Repeat the valve timing check.

Installation

Further installation is carried out in the reverse order, while the following must be taken into account: the hoses and hose nipple of the air boost system must be cleaned of oils and grease before installation. Do not use lubricants under any circumstances. Install the engine mount. Install the lower central part of the belt guard. Install the torsional vibration damper. Install the bracket together with the engine mount. Install the upper part of the belt guard. Install the air ducts in the clamps. Install the poly V-belt. Install the wiper arm.

Tightening torques: