AUDI A4 1999 B5 / 1.G APB Engine Assembly Workshop Manual

13-1


Engine, disassembly and
assembly

Ribbed belt, removing and installing


Removing

Repair Manual, Body Exterior, Repair Group 63
- Remove noise insulation -arrows-.
- Remove bumper
- Move lock carrier to service position

Note:
Viscous fan has left-hand thread: turn in direction indicated. - Remove viscous fan (counter-hold with pin wrench 3212).
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13-2

- Mark direction of rotation of ribbed belt.

Note:
Mark the direction of rotation of the ribbed belt with chalk or felt pen
before removing. A used belt can break if it rotates in the opposite
direction when reinstalled. - To slacken ribbed belt, turn to the right using a 17 mm ring spanner
until the two holes are aligned with each other -arrow- and hold in
position with mandrel 3204.
- Take off ribbed belt.
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13-3

Installing

Routing of ribbed belt - Install ribbed belt onto crankshaft pulley and idler wheel first, and push
belt onto tensioning roller last.
D1 - vehicles without air conditionerD2 - vehicles with air conditioner
- Take out mandrel 3204.

Note:
Viscous fan has left-hand thread: turn against direction indicated.
Repair Manual, Body Exterior, Repair Group 50

Repair Manual, Body Exterior, Repair Group 63 - Counter-hold belt pulley for viscous fan using spanner wrench 3212
and tighten viscous fan using open end spanner 3312 and torque
wrench 1331 (left hand thread).
- Install lock carrier.
- Install bumper.- Install noise insulation.
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13-4

Toothed belt, removing and installing


Removing

- Remove ribbed belt Page 13
-1 .

- Remove bolts -arrows- and remove engine cover panel -C-.

- Remove pressure hoses -arrows- between charge air coolers and
pressure pipes (left and right sides).
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13-5


Note:
Watch position of retaining strips -2-. - Remove pressure pipes -1-.

- Remove tensioner -1- for ribbed belt.
- Remove left and right toothed belt guards -2-.
- Remove center toothed belt guard -3-.
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13-6


Note:
Turn over the engine at the central bolt on the crankshaft.
CAUTION!
Injury risk - do not turn engine while feeling for TDC drilling. - Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.
- Check position of camshafts: larger holes in securing plates on
camshaft sprockets must align opposite one another on inside. If not,
turn crankshaft one revolution further.
- Remove sealing plug from cylinder block, left.
- The TDC drilling in the crankshaft must be visible (or able to be felt) in
line with the sealing plug hole.

- Screw clamping bolt 3242 for crankshaft into sealing plug hole and
tighten.
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13-7


Note:
The central bolt does not have to be loosened to remove the vibration
damper. - Remove vibration damper on crankshaft.

- Remove idler wheel for ribbed belt -arrows-.
- Remove toothed belt guard behind vibration damper -arrows-.
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13-8

Note:

Mark the direction of rotation of the toothed belt
with chalk or felt pen before removing. A used
belt can break if it rotates in the wrong direction
when reinstalled.
The toothed belt tensioning element is oil-
damped and can therefore only be compressed
slowly by applying constant pressure.

- Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm
in direction of arrow until tensioning lever -2- compresses tensioning
element -3- sufficiently to enable special tool T 400 11 to be fitted in
drilling and in plunger.
- Insert special tool T 400 11, release toothed belt tensioning roller.
- Take off toothed belt.
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13-9

Installing

- Insert camshaft clamp 3391 in securing plates of
two camshafts.

- Slacken both camshaft bolts and remove
approx. 5 turns.

- Take out camshaft clamp 3391.

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. - Pull off both camshaft sprockets with special tool T40001.
- Reinstall both camshaft sprockets with securing plates and tighten
hand-tight again.

- Install toothed belt on all sprockets as illustrated.
- Install camshaft clamp 3391.
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13-10


- Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm
in direction of arrow until special tool T 400 11 can be removed.

- Pre-tension toothed belt by a turning in direction of arrow with a torque
of 15 Nm using a torque wrench.
- Tighten bolts on camshaft sprockets.
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