engine AUDI TT 1999 8N / 1.G AEB ATW Engines Engine Assembly Workshop Manual

13-1


Engine, disassembling and
assembling Lock carrier, moving into service position

Special tools and equipment
3369 support tool
1 -
Bolts
45 Nm (33 ft lb)
2 -
Bolts 45 Nm (33 ft lb)
3 -
Bolts 10 Nm (7 ft lb)
4 -
Bolts 10 Nm (7 ft lb)
5 -
Bore For 3369 support tool
6 -
Lock carrier bore
7 -
Fender bore
Pa
ge 1 of 38 En
gine, disassemblin
g and assemblin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.1

13-17

Installing

Note:
When installing ribbed belt, make sure it is
seated correctly on the pulley.

- Place ribbed belt on belt pulleys for crankshaft,
viscous fan and power steering pump, (use tools
to pull up if necessary).

- Move ribbed belt tensioner in direction of arrow.
- Install ribbed belt on belt pulley for generator last and release tension
on belt tensioner.
- Check ribbed belt for proper installation.
Ribbed belt routing Page 13
-12
- Install ribbed belt for A/C compressor.
Ribbed belt routing Page 13
-12

- Use torque wrench to pre-tighten belt tensioner hex screw to 25 Nm
(18 ft lb).
- Tighten bolts -A- to 20 Nm (15 ft lb) at same time.
- Start engine and check running of belt.
Pa
ge 19 of 38 En
gine, disassemblin
g and assemblin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.1

13-19

Installing
Installation is the reverse of removal, noting the
following:

- Install V-belt and loosely bolt both halves of belt
pulley to coolant pump.

- Slowly bring belt pulley halves together by
turning coolant pump and tightening bolts for
belt pulley in stages.

While tightening pulley halves, the V-belt must
move outward and sit correctly on belt pulley.

- Tighten bolts to 25 Nm (18 ft lb).

Note:
Adjustment of V-belt tension for coolant pump is
not possible.

- Install ribbed belt and release tension on
tensioner.

- Start engine and check running of belt.

- Check tightening torque of bolts for coolant
pump belt pulley.
Pa
ge 21 of 38 En
gine, disassemblin
g and assemblin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.1

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).
Pa
ge 32 of 38 En
gine, disassemblin
g and assemblin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.1

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.
Pa
ge 35 of 38 En
gine, disassemblin
g and assemblin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.1

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
.
Pa
ge 37 of 38 En
gine, disassemblin
g and assemblin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.1