AUDI A6 1996 C5 / 2.G AEB ATW Engines Engine Assembly Owner's Guide

13-28


Thin rib of camshaft gear points outward (arrows) and TDC Cyl. 1 marking
is visible. Fig. 1 Installation position for camshaft gear
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13-29

Toothed belt, removing and installing


Removing

Engine installed
Lock carrier in service position Page 13
-1

Special tools and equipment
V159 pin wrench

- Remove ribbed belt and ribbed belt tensioner
Page 13
-15
.

- Remove viscous clutch (with belt pulley) Page
13
-14
, Fig. 1
.

- Remove upper toothed belt cover.

CAUTION!

Before removing toothed belt, note direction
of rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used
belt can destroy the belt.

- Turn crankshaft at central bolt of toothed belt gear in direction of
engine rotation to TDC Cyl.1 marking (arrows).
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13-30


- Remove vibration damper.

- Remove lower toothed belt cover (arrows).
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13-31


-
Using Torx wrench T45, loosen toothed belt tensioner (lower arrow).- Push toothed belt tensioner downward.
- Remove toothed belt.
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13-32

Installing (adjust valve timing)

Note:

Use the following procedure to adjust toothed
belt, even for repairs that only require removal
of toothed belt from camshaft gear.
Adjustments can be made on a hot or cold
engine.

CAUTION!

When turning camshaft, crankshaft may not
be at TDC for any cylinder. Valves and/or
piston heads may be damaged.

- Align marking on camshaft gear to marking on cylinder head cover.
- Place toothed belt on crankshaft gear noting direction of rotation.
- Install lower toothed belt cover.
- Using a bolt, secure vibration damper/belt pulley (note locating point).
- Set crankshaft to TDC Cyl. 1 position.
- Place toothed belt on belt tensioner and camshaft gear.
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- Tighten toothed belt by turning tensioner -A- to right using 2 pin
spanner (i.e. Matra V159 pin wrench) until cylinder -1- is fully extended
and tensioner -2- is raised by approx. 1 mm.
- Tighten mounting bolt -3- hand tight.
- Turn crankshaft 2 rotations in running direction.

Note:
If edge of piston is located in area -A-, measurement -D- is between 25-29
mm (0.984-1.142 in.). - Check area -A- for proper alignment with the upper edge of piston -2-
(Fig. A13-0012) and adjust if necessary.

Area -A-: adjustment OK
Area -B-: wear limit
Area -C-: re-adjust and check belt drive including tensioner for
wear
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13-34


- Counterhold toothed belt tensioner using 2 pin spanner -B- and tighten
mounting screw -3-.

Note:
When installing the ribbed belt, make sure it is seated correctly on the
pulley. - Turn crankshaft at central bolt for toothed belt gear two rotations in
direction of engine rotation, until camshaft and crankshaft markings
align with their respective reference points.
- Install vibration damper/belt pulley.
- Install upper toothed belt cover.
- Install ribbed belt and ribbed belt tensioner Page 13
-17
.
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13-35

Tightening torques

Component

Tightening
torque
Toothed belt tensioner to
tensioner assembly
25 Nm (18 ft
lb)
Lower toothed belt cover
to
cylinder block M6 10 Nm (7 ft lb)
M8 20 Nm (15 ft
lb)
Vibration damper/belt pulley to
crankshaft
40 Nm (30 ft lb)
1)
Ribbed belt tensioner to
mounting bracket
25 Nm (18 ft
lb)
1) Bolt strength grade: 10.9
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