Audi Cars 1999-05

Accessory Drive Belts 2

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Removal & Installation




NOTE
To access the front of the engine on the Audi A4 and 1998 and later Passat models, the lock carrier for the hood latch must be placed in the service position.

If a belt must be replaced, the driven component must be loosened and moved to its extreme loosest position (usually by moving it toward the center of the motor). On models with automatic belt adjusters, the tensioner is moved to release tension on the belt, and then the belt is removed.

  1. After removing the old belt, check the pulleys for dirt or built-up material which could affect belt contact.
  2.  
  3. Carefully install the new belt, it may appear to be just a little too small to fit over the pulley flanges. Fit the belt over the largest pulley (usually the crankshaft pulley at the bottom center of the motor) first, then work on the smaller one(s). Gentle pressure in the direction of rotation is helpful.
  4.  


NOTE
Some belts run around a third or idler pulley, which acts as an additional pivot in the belt's path. It may be possible to loosen the idler pulley as well as the main component, making your job much easier. Depending on which belt(s) you are changing, it may be necessary to loosen or remove other interfering belts to get at the one(s) you want.

The 1.8L engines use three dive belts, two multi-ribbed, and a V-belt. The alternator, cooling fan and power steering pump are driven by a serpentine belt that is tensioned by a conventional automatic tensioner. The water pump is drive by second pulley mounted to the power steering pump. A separate multi-ribbed belt drives the air conditioner. It uses a tensioning roller that must be preloaded and tightened in place to tension.

  1. To remove and install the belts on the 1.8L engine, proceed as follows:
  2.  
  3. On 1.8L engines the water pump pulley is a split sheave type pulley. To remove the water pump drive belt:
  4.  
    1. First remove the multi-ribbed drive belt.
    2.  
    3. Use an open-end wrench to loosen the tensioner. Move the tensioner until the tensioner and housing holes align, then place a suitable hex tool or drift into the aligned holes to keep the tensioner retracted.
    4.  
    5. Remove the belt.
    6.  
    7. Counterhold the viscous fan pulley using a suitable drift.
    8.  
    9. Remove the pulley fastener using an 8 mm hex wrench, and then remove the fan along with the fan pulley.
    10.  
    11. The water pump drive belt is removed by removing the fasteners for the pump's pulley. Counter hold the power steering pump pulley to allow for removal of the water pump pulley by placing a suitable dowel through the upper back side of the power steering pump pulley.
    12.  
    13. During assembly, rotate the power steering pump occasionally to properly seat the belt. There is no adjustment shims available, therefore if the belt is in need of replacement, an exact original fit must be used. If the belt is too loose it will slip, and if too tight it will damage the bearings of the power steering pump and water pump, causing a premature failure.
    14.  
    15. The rest of the reassembly procedure is in reverse order of removal.
    16.  

  5. To remove the air conditioner belt:
  6.  
    1. Loosen the two fasteners for the tensioner assembly
    2.  
    3. Move the tensioner to slacken the belt.
    4.  
    5. Remove the belt.
    6.  
    7. Reassemble in reverse order of removal. Tension the belt by applying an 18 ft. lb. (25 Nm) load on the tensioner assembly and tightening the fasteners.
    8.  


When buying replacement belts, remember that the fit is critical according to the length of the belt, the width of the belt, the depth of the belt and the angle or profile of the V shape (always match up old belt with new belt if possible). The belt shape should exactly match the shape of the pulley; belts that are not an exact match can cause noise, slippage and premature failure.

After the new belt is installed, adjust it for proper tension. This is sometimes a three or four-handed job; you may find an assistant helpful. Make sure that all the bolts you loosened are retightened and that any other loosened belts have the correct tension. A new belt can be expected to stretch a bit after installation so be prepared to re-adjust your new belt.


NOTE
After installing a new belt, run the engine for about 5 minutes and then recheck the belt tension.



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Fig. When removing ribbed belts, it's a good idea to mark the rotation direction of the belt if it is to be reused



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Fig. Ribbed style serpentine belt



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Fig. On 1.8L engines, use an open-end wrench to move the automatic tensioner. Align the tensioner and housing holes. Lock it in place using a suitable drift



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Fig. The tensioner assembly on the 1.8L engine shown retracted using a suitable hex tool



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Fig. On 1.8L engines, remove the fan pulley by counter holding it with a suitable drift, and loosen the fastener with an 8 mm hex wrench



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Fig. On 1.8L engines, loosen the air conditioner tensioner fasteners to allow for belt removal



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Fig. To tension the air conditioner belt on 1.8L engines, apply an 18 ft. lb. (25 Nm) load on the tensioner, and then tighten the fasteners



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Fig. On V6 engines, pivot the tensioner clockwise until the two holes are aligned and insert a suitable drift to keep it retracted

Key List for 93221g16:

Belt tensioner

Tensioning lever

Tensioning element



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Fig. Belt routing for the 1.8L engines



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Fig. Belt routing for the V6 engine



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Fig. Belt routing for the VR6 engine



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Fig. Belt routing for the 1995-96 Passat 2.0L ABA engine



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Fig. The 1.8L A/C belt is accessed from under the vehicle



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Fig. The belt tensioner on the 1.8L engine is held retracted using a suitable drift of hex key wrench

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Pivot the belt tensioner pulley and remove the belt from the alternator pulley.
  4.  
  5. Remove the center and right engine undercovers.
  6.  
  7. Remove the belt from the remaining pulleys.
  8.  
  9. Installation is the reverse of the removal procedure.
  10.  

 
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