Audi Cars 1999-05

Timing Belt, Cover & Seal

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Removal & Installation



1.8L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. From under the vehicle, remove the splash shield.
  6.  
  7. Remove the front bumper.
  8.  
  9. Remove the intake air duct between the grille/front end assembly and the air cleaner housing.
  10.  
  11. Remove the grille/front end assembly-to-chassis bolts and the grille/front end assembly-to-vehicle fasteners.
  12.  
  13. If installed, remove the wiring harness retaining clamps from the left side of the radiator frame.
  14.  
  15. Install Support tools 3369 bolts into the grille/front end assembly-to-chassis holes; then, pull the grille/front end assembly forward until it hits the stops.
    NOTE
    If necessary to secure the grille/front end assembly, install M6 bolts into the rear bored holes of the grille/front end assembly and the fender.

  16.  
  17. Loosen the A/C compressor-s serpentine belt tensioner bolts; release the belt tension and remove the belt.
  18.  
  19. Place an open-end wrench on the alternator belt tensioner and rotate it clockwise toward the alternator to release the belt-s tension. Remove the alternator serpentine drive belt and release the tensioner.
    NOTE
    If necessary to lock the alternator tensioner in position, align the housing holes and insert an Allen wrench into the holes to secure its movement.

  20.  
  21. Using a 5 x 60mm bolt, secure the viscous fan pulley. Using a hex wrench, remove the viscous fan-to-pulley bolts. Remove the viscous fan assembly.
  22.  
  23. Remove the upper timing belt cover.
    NOTE
    If reusing the timing belt, mark its rotational direction so it may be installed in its original position.

  24.  
  25. Using the center bolt, rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  26.  
  27. Remove the damper pulley-to-crankshaft bolts and the damper.
  28.  
  29. Remove the lower timing belt cover.
  30.  
  31. Using a Torx Wrench T45, loosen the timing belt tensioner, push the tensioner downward and remove the timing belt.

    Click image to see an enlarged view

    Fig. Crankshaft pulley and camshaft sprocket alignment locations-Audi A4 1.8L 4-Cyl engine



    Click image to see an enlarged view

    Fig. Timing belt tension adjustment-Audi A4 1.8L 4-Cyl engine



    Click image to see an enlarged view

    Fig. Timing belt tension wear limits-Audi A4 1.8L 4-Cyl engine

  32.  

To install:

  1. Align the camshaft sprocket timing mark with the cylinder head cover mark.
  2.  
  3. Install the timing belt on the crankshaft sprocket with the arrow facing the rotational direction.
  4.  
  5. Install the lower timing belt cover.
  6.  
  7. Using a bolt, secure the damper/belt pulley on the crankshaft.
  8.  
  9. Align the crankshaft damper/belt pulley with the housing timing mark so that the No. 1 cylinder is at TDC of its compression stroke.
  10.  
  11. Install the timing belt on the camshaft sprocket and belt tensioner.
  12.  
  13. Using a 2-pin Spanner Matra V159 Wrench, lift (turn clockwise) the timing belt tensioner cylinder No. 1 until it is fully extended and tensioner cylinder No. 2 is raised approx. 1mm; then, hand-tighten the mounting bolt.
  14.  
  15. Rotate the crankshaft 2 complete rotation in the running direction.
  16.  
  17. Inspect area -A- for proper alignment with the upper edge of piston No. 2 and adjust if necessary.
    NOTE
    If the piston edge is located in area -A-, measurement -D- is 0.984-1.142 in. (25-29mm).



    Area -A- - adjustment OK
     
    Area -B- - wear limit
     
    Area -C- - re-adjust and check belt drive including tensioner for wear.
     

  18.  
  19. After adjustment has been verified, secure the tensioner with a 2-pin Spanner Matra V159 Wrench and tighten the mounting bolt.
  20.  
  21. Complete the damper to crankshaft installation.
  22.  
  23. Using the center bolt, rotate the crankshaft 2 rotations in the direction of engine rotation until the camshaft and crankshaft marks align with their respective reference points.
  24.  
  25. Install the upper timing belt cover.
  26.  
  27. Install the drive belts.
  28.  
  29. Replace the remaining components by reversing the removal procedures.
  30.  
  31. Install the negative battery cable last.
  32.  
  33. Test drive the vehicle.
  34.  

2.7L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect negative battery cable .
  4.  
  5. Remove the front bumper.
  6.  
  7. Place the hood lock carrier in the service position.
  8.  
  9. Remove the serpentine drive belt by performing the following procedure:
  10.  
  11. Using Spanner Wrench No. 3212, secure the viscous fan pulley. Using an Open-end Spanner Wrench 3312, remove the viscous fan bearing housing by turning it clockwise.
    NOTE
    The viscous fan is mounted with a left-handed thread; turn it clockwise to loosen it.

  12.  
  13. Place a 17mm box wrench on the serpentine drive belt tensioner and turn the tensioner clockwise until the 2 holes align; insert drift 3204 into the holes to secure the tensioner in place.
  14.  
  15. Mark the running direction of the serpentine drive belt and remove it from the pulleys.
  16.  
  17. Remove the top engine covers.
  18.  
  19. Remove the pressure hoses between charge air coolers and pressure lines.
  20.  
  21. Remove the pressure hoses located at the front of the engine.
  22.  
  23. Remove the timing belt tensioner.
  24.  
  25. Remove all three timing belt covers.
  26.  
  27. Rotate the crankshaft by hand to align the crankshaft pulley mark with the arrow on the engine housing and the large hole in each camshaft sprocket must face inward and must align; this should be Top Dead Center (TDC) of the No. 1 cylinder-s compression stroke. If these conditions are not correct, rotate the crankshaft one complete revolution and realign.
  28.  
  29. On the left side of the cylinder block near the crankshaft, remove the sealing plug.
  30.  
  31. Insert Crankshaft Holder tool No. 3242 into the sealing plug hole to secure the crankshaft.
  32.  
  33. Remove the damper-to-crankshaft bolts and the damper.
    NOTE
    It is not necessary to remove the center bolt when removing the crankshaft damper.

  34.  
  35. Remove the serpentine belt idler and the crankshaft damper guard.
  36.  
  37. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, insert a 2mm spring pin through the tensioner housing and tensioner plunger to secure it in place. When the plunger is secure, release the wrench tension.
  38.  
  39. Mark the running direction of the timing belt and remove it from the pulleys.

    Click image to see an enlarged view

    Fig. Crankshaft pulley alignment location for TDC-Audi 2.7L V6 engine



    Click image to see an enlarged view

    Fig. View of crankshaft holding tool installed-Audi 2.7L V6 engine

  40.  

To install:

  1. Insert camshaft clamp 3391 in the securing plates of both camshaft sprockets.
  2.  
  3. Loosen both camshaft bolts and remove approximately 5 turns.
  4.  
  5. Remove the camshaft clamp.
  6.  
  7. Pull off both camshaft sprockets with special tool T40001.
  8.  
  9. Reinstall both camshaft sprockets with securing plates and tighten hand-tight again.
    NOTE
    The camshaft sprockets should be just tight enough on the camshaft tapers so that they can still be turned but do not move axially.

  10.  
  11. Install the timing belt; make sure the timing belt is installed in the correct running direction from which it was removed.
  12.  
  13. Reinstall the camshaft clamp.
  14.  
  15. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, remove the 2mm spring pin from the tensioner housing. Using a torque wrench, turn tensioner roller counterclockwise to 11 ft. lbs. (15 Nm) to put pressure on the timing belt.
  16.  
  17. Tighten he camshaft sprocket bolts. Torque the bolts to 41 ft. lbs. (55 Nm).
  18.  
  19. Install the crankshaft damper guard and the serpentine belt idler pulley; torque the idler pulley bolts to 33 ft. lbs. (45 Nm).
  20.  
  21. Install the crankshaft damper and torque the damper-to-crankshaft bolts to 15 ft. lbs. (20 Nm). If the damper-to-crankshaft center bolt was removed, torque it to 147 ft. lbs. (200 Nm) plus 180°.
  22.  
  23. Remove the Crankshaft Holder tool No. 3242 and install the sealing plug.
  24.  
  25. Replace the remaining components by reversing the removal procedures.
  26.  
  27. Connect the electrical connectors. Install the negative battery cable last.
  28.  
  29. Test drive the vehicle.
  30.  

2.8L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the upper engine cover.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. From under the vehicle, remove the splash shield.
  8.  
  9. Remove the front bumper.
  10.  
  11. Disengage the hood lock cable
  12.  
  13. Remove the intake air duct between the lock carrier and the air cleaner housing at the grille/front end assembly.
  14.  
  15. Remove the grille/front end assembly-to-chassis bolts.
  16.  
  17. Disconnect the electrical connectors from the grille/front end assembly.
  18.  
  19. Drain the engine coolant and disconnect the coolant hoses from the radiator.
  20.  
  21. Detach the A/C condenser from the grille/front end assembly and suspend it on a wire at the front wheel.
    WARNING
    DO NOT suspend the condenser by its lines. The condenser lines must not be bent or kinked.

  22.  
  23. Drain the automatic transmission fluid from the transmission and the transmission cooler. Disconnect the hydraulic lines from the transmission cooler.
  24.  
  25. If equipped, remove the charge air cooler.
  26.  
  27. Remove the grille/front end assembly-to-vehicle fasteners and the grille/front end assembly from the vehicle.
  28.  
  29. Remove the serpentine drive belt by performing the following procedure:
    1. Using Spanner Wrench No. 3212, secure the viscous fan pulley. Using an Open-end Spanner Wrench 3212, remove the viscous fan bearing housing by turning it clockwise.
      NOTE
      The viscous fan is mounted with a left-handed thread; turn it clockwise to loosen it.

    2.  
    3. Place a 17mm box wrench on the serpentine drive belt tensioner and turn the tensioner clockwise until the 2 holes align; insert drift 3204 into the holes to secure the tensioner in place.
    4.  
    5. Mark the running direction of the serpentine drive belt and remove it from the pulleys.
    6.  

  30.  
  31. Rotate the crankshaft by hand to align the crankshaft pulley mark with the arrow on the engine housing and the large hole in each camshaft sprocket must face inward and must align; this should be Top Dead Center (TDC) of the No. 1 cylinder-s compression stroke. If these conditions are not correct, rotate the crankshaft one complete revolution and realign.
  32.  
  33. On the left side of the cylinder block near the crankshaft, remove the sealing plug.
  34.  
  35. Insert Crankshaft Holder tool No. 3242 into the sealing plug hole to secure the crankshaft.
  36.  
  37. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, insert a 2mm spring pin through the tensioner housing and tensioner plunger to secure it in place. When the plunger is secure, release the wrench tension.
  38.  
  39. Remove the damper-to-crankshaft bolts and the damper.
    NOTE
    It is not necessary to remove the center bolt when removing the crankshaft damper.

  40.  
  41. Remove the serpentine belt idler and the crankshaft damper guard.
  42.  
  43. Mark the running direction of the timing belt and remove it from the pulleys.

    Click image to see an enlarged view

    Fig. Crankshaft pulley alignment location for TDC-Audi 2.8L V6 engine



    Click image to see an enlarged view

    Fig. Left camshaft sprocket alignment position for TDC; right camshaft position is similar-Audi 2.8L V6 engine



    Click image to see an enlarged view

    Fig. View of crankshaft holding tool installed-Audi 2.8L V6 engine



    Click image to see an enlarged view

    Fig. View of camshaft locator bar installed-Audi 2.8L V6 engine

  44.  

To install:

  1. Make sure that the camshaft pulleys and the crankshaft pulley are in alignment with TDC of the No. 1 cylinder-s compression stroke.
  2.  
  3. Install the timing belt; make sure the timing belt is installed in the correct running direction from which it was removed.
  4.  
  5. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, remove the 2mm spring pin from the tensioner housing. Slowly, release the tensioner spring pressure to put pressure on the timing belt.
  6.  
  7. Install the crankshaft damper guard and the serpentine belt idler pulley; torque the idler pulley bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the crankshaft damper and torque the damper-to-crankshaft bolts to 15 ft. lbs. If the damper-to-crankshaft center bolt was removed, torque it to 147 ft. lbs. (200 Nm) plus 180° 1 / 2 turn).
  10.  
  11. Remove the Crankshaft Holder tool No. 3242 and install the sealing plug.
  12.  
  13. Replace the remaining components by reversing the removal procedures.
  14.  
  15. Refill the cooling system and the automatic transaxle. Connect the electrical connectors. Install the negative battery cable last.
  16.  
  17. Test drive the vehicle.
  18.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Place the hood lock carrier in the service position.
  6.  
  7. Remove the serpentine drive belt by turning belt tensioner clockwise using tensioner tool 3299.
  8.  
  9. Mark the running direction of the serpentine drive belt and remove it from the pulleys.
  10.  
  11. Remove the serpentine belt tensioner.
  12.  
  13. Remove power steering pump pulley.
  14.  
  15. Remove the harmonic balancer and thrust washer.
  16.  
  17. Remove 12 bolts and the timing belt covers.
  18.  
  19. Remove the rear engine cover.
  20.  
  21. Remove the coolant expansion tank and set to one side with hoses attached.
  22.  
  23. Remove all necessary wiring connectors and hoses, and remove air filter housing.
  24.  
  25. Remove the oil dipstick guide tube.
  26.  
  27. Disconnect all ignition coil electrical connectors.
  28.  
  29. Remove both cylinder head covers by removing screws in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head cover removal sequence-Audi 3.0L engine (same for both head covers)

  30.  
  31. Turn crankshaft until camshaft lobes at cylinder no. 3 on right cylinder head point upward.
  32.  
  33. Install camshaft adjuster gauge T40030 on right cylinder head camshafts.
  34.  
  35. Spread adjuster gauge using wrench on threaded shaft until gauge is seated without end play.
  36.  
  37. Install camshaft adjuster gauge T4030 on left cylinder head camshafts.
  38.  
  39. Spread adjuster gauge using wrench on threaded shaft until gauge is seated without end play.

    Click image to see an enlarged view

    Fig. Right side camshaft lobes positioning-Audi 3.0L engine



    Click image to see an enlarged view

    Fig. Installing camshaft adjuster gauge on right cylinder head-Audi 3.0L engine



    Click image to see an enlarged view

    Fig. Installing camshaft adjuster gauge on left cylinder head-Audi 3.0L engine

  40.  
  41. On the left side of the cylinder block near the crankshaft, remove the sealing plug.
  42.  
  43. Insert Crankshaft Holder tool No. 3242 into the sealing plug hole to secure the crankshaft.
  44.  
  45. Remove securing ring from all camshaft gears.
  46.  
  47. Loosen, but do not remove all camshaft gear mounting bolts.
  48.  
  49. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, insert a 2mm spring pin through the tensioner housing and tensioner plunger to secure it in place. When the plunger is secure, release the wrench tension.
  50.  
  51. Mark the running direction of the timing belt, loosen eccentric pulley bolt and remove timing belt from the pulleys.
  52.  

To install:


NOTE
Replace gaskets, O-rings and self-locking bolts.


NOTE
When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged.

  1. Bolt in the camshaft gears 1 to 4 far enough so they can still just be turned without canting.
  2.  
  3. Install the timing belt so it makes exact contact with front edge of all toothed belt gears.
  4.  
  5. Using 3387 pin wrench, turn the eccentric pulley clockwise until the handle of the pin wrench is exactly above the center axle of coolant pump gear.

    Click image to see an enlarged view

    Fig. Positioning eccentric pulley for timing belt installation-Audi 3.0L engine

  6.  
  7. Hold pin wrench in this position and torque eccentric bolt to 33 ft. lbs. (45 Nm).
  8.  
  9. Place a torque wrench horizontally on socket head of the tensioning lever and turn bolt using 33 ft. lbs. (45 Nm) of torque, to pretension the timing belt.
  10.  
  11. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, remove the 2mm spring pin from the tensioner housing. Using a torque wrench, turn tensioner roller counterclockwise to 11 ft. lbs. (15 Nm) to put pressure on the timing belt.
  12.  
  13. Place a torque wrench horizontally on socket head of the tensioning lever and turn bolt using 18 ft. lbs. (25 Nm) of torque, to tension the timing belt.
  14.  
  15. Place T40028 socket at camshaft adjuster of exhaust camshaft on left cylinder bank.
  16.  
  17. Turn rotor of camshaft adjuster clockwise to 84 inch lbs. (10 Nm).
  18.  
  19. Turn rotor of camshaft adjuster at right cylinder bank clockwise to 84 inch lbs. (10 Nm).
  20.  
  21. Torque bolts for all four camshaft gears to 74 ft. lbs. (100 Nm).
  22.  
  23. Install caps with new O-rings at camshaft gears and secure them with the securing ring.
  24.  
  25. Remove the T40030 camshaft adjuster gauge.
  26.  
  27. Remove the alignment bolt and thread sealing plug of TDC opening in using new O-ring.
  28.  
  29. Install remaining components in reverse order of removal. Torque cylinder covers to 84 inch lbs. (10 Nm) using same sequence as removal.
  30.  

4.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
    NOTE
    The battery is located in the luggage compartment, right side, under a cover.

  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Cylinder head covers
     
    Spring clips at timing belt cover
     
    Timing belt cover
     
    Sound insulation from rear of timing cover
     
    Accessory drive belt
     

  6.  
  7. Turn crankshaft to TDC by hand to align timing marks
  8.  
  9. Check position of camshafts; ensure larger holes in securing plates on sprockets align with each other and are facing inward (if not, turn crankshaft one revolution).
  10.  
  11. Remove seal plug from left side of cylinder block and check that the TDC drilling in the crankshaft is aligned in the hole. Then screw in a clamping bolt (3242) to hold this position.
  12.  
  13. Remove or disconnect the following:
    NOTE
    Mark the direction of rotation of the timing belt before removing.


    NOTE
    The timing belt tensioner is oil-filled. To compress the tensioner, apply a slow, constant pressure.



    Serpentine drive belt tensioner
     
    Vibration damper
     
    Torque support
     

  14.  
  15. With an 8mm Allen key, turn the timing belt tensioner in a counterclockwise direction until the tensioner is compressed far enough to insert a holding pin T40011 into the drilled hole and into the plunger.
  16.  
  17. Install a camshaft holding bar T40005 onto the securing plated of the two camshafts.
  18.  
  19. Loosen two camshaft bolts about five turns, and then remove the camshaft holding bar.
  20.  
  21. With a puller, remove the camshaft sprocket from the camshaft.
  22.  
  23. Loosen the timing belt tensioning idler and remove the timing belt with the camshaft sprocket for bank 1-4. Do not change position of belt on sprocket.
  24.  

To install:

Click image to see an enlarged view

Fig. Showing timing belt routing-4.2L engines



Click image to see an enlarged view

Fig. Inserting drill bit between tensioner and hydraulic piston-4.2L engines



Click image to see an enlarged view

Fig. Measuring dimension -a- between timing belt tensioning lever and hydraulic tensioning element-4.2L engines

  1. Ensure all pulleys, timing belt idlers and wheels are installed. Torque bolts as follows:

    Idler wheel: 33 ft. lbs. (45 Nm)
     
    Tensioning roller: 15 ft. lbs. (20 Nm)
     
    Pulley to crankshaft: 15 ft. lbs. (20 Nm)
     
    Timing belt tensioner: 7 ft. lbs. (10 Nm)
     
    Eccentric wheel: 16 ft. lbs. (22 Nm)
     
    Center bolt to crankshaft: 148 ft. lbs. (200 Nm), plus 180 degrees
     

  2.  
  3. First, install the timing belt onto the crankshaft sprocket, idler wheel for tensioner, tensioning roller, camshaft sprocket for bank 5-8, coolant pump, and damper wheel.
  4.  
  5. Then, take camshaft sprocket for cylinder bank 1-4 and install timing belt and bolt sprocket onto camshaft.
  6.  
  7. Lightly secure both camshaft sprockets with securing plates by tightening hand tight.
    NOTE
    Camshaft sprockets must be tight enough on the camshaft tapers to be turned, but not to be moveable axially.

  8.  
  9. Reinstall the camshaft holding bar T40005.
  10.  
  11. Insert a 5mm drill bit between the tensioner and hydraulic piston.
  12.  
  13. Tension the timing belt initially to 35 inch lbs. (4 Nm), using tensioning key T40009 and torque wrench with socket attachment VAS 5122 by turning in a counterclockwise direction. Then, tighten the eccentric wheel to 16 ft. lbs. (22 Nm).
  14.  
  15. Using the 8mm Allen key, turn the timing belt tensioning lever to the left until the insert pin T40011 can be removed.
  16.  
  17. Remove the camshaft holding bar T40005, 5mm drill bit, and crankshaft clamping bolt 3242 and reinstall the sealing plug in the hole.
  18.  
  19. Tighten the camshaft sprocket bolts to 41 ft. lbs. (55 Nm).
  20.  
  21. Turn the crankshaft two revolutions.
  22.  
  23. Measure the dimension between the timing belt tensioning lever and the hydraulic tensioning element (dimension -a-). If dimension is not 5mm, readjust the tensioning roller as needed.
  24.  
  25. Measure the clearance between the timing belt guard and outer surface of timing belt (at both cam sprockets). The clearance should be 1mm. If not, adjust cover until clearance is set.
  26.  
  27. Install all remaining components in reverse of removal procedure.
  28.