power steering AUDI TT 1996 8N / 1.G AEB ATW Engines Engine Assembly Workshop Manual

13-4


Ribbed belt for power steering pump,
generator and viscous fan, and V-belt for
coolant pump

CAUTION!
Before removing ribbed belt, note direction of
rotation with chalk or felt-tip marker. Reversing
the direction of rotation of a used belt can
destroy the belt. When installing the ribbed belt,
make sure it is seated correctly on the pulley.
1 -
Fan wheel bolt
10 Nm (7 ft lb)
2 -
Fan wheel For viscous fanRemoving and installing Page 13
-14
,
Fig. 1

3 -
Coolant pump pulley bolt
25 Nm (18 ft lb)
4 -
Belt pulley For coolant pumpV-belt designInstalled position: straight side toward
coolant pump
Pa
ge 4 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

13-6


11 -
Circlip
For viscous fan bearingRemoving and installing Page 13
-20
12 -
Bolt for belt pulley
10 Nm (7 ft lb)
13 -
Bearing For viscous fanRemoving and installing Page 13
-20
14 -
T-head bolt
Insert before installing bracket for
generator, power steering pump and
viscous fan
15 -
Nut 40 Nm (30 Nm)
16 -
Bolt 25 Nm (18 ft lb)
Pa
ge 6 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

13-8


22 -
Brace
For intake manifold
23 -
Bolt 20 Nm (15 ft lb)
24 -
Bolt 40 Nm (30 ft lb)
25 -
Bolt 25 Nm (18 ft lb)
26 -
Bolt 25 Nm (18 ft lb)
27 -
Bracket For generator, power steering pump and
viscous fan Removing and installing Page 13
-22
Different length boltsArrangement and tightening sequence
Page 19
-16

28 -
Power steering pump
Removing and installing Repair Manual, Suspension, Wheels, Steering, Repair Group 48

29 -
Bolt
Pa
ge 9 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

13-9


30 -
Coolant pump
With coolant regulatorRemoving and installing Page 19
-13
31 -
Belt pulley
For power steering pumpDesigned for ribbed beltInstall with bulged side facing in driving
direction
32 -
Belt pulley For power steering pumpDesigned for ribbed belt
33 -
Bolt 25 Nm (18 ft lb)
34 -
V-belt For coolant pumpRemoving and installing Page 13
-18
35 -
Viscous clutch
Removing and installing Page 13
-14
,
Fig. 1

Pa
ge 11 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

13-12


V-belt and ribbed belt, routing overview

1 -
Ribbed belt tensioner
2 -
Generator
3 -
Viscous clutch
4 -
Coolant pump
5 -
Power steering pump
6 -
V-belt
For coolant pumpRemoving and installing Page 13
-18
7 -
Ribbed belt
For generator, power steering pump and
viscous fan Removing and installing Page 13
-15
Pa
ge 14 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

13-18

V-belt, removing and installing


Lock carrier in service position Page 13
-
17


Ribbed belt free of tension Page 13
-15


Removing

- Remove noise insulation panel (arrows).
- Remove viscous fan (with belt pulley) from bearing Page 13
-14
, Fig.
1
.

- Remove belt pulley for coolant pump. Use drift (arrow) to counterhold
at belt pulley for power steering pump.
- Remove V-belt.
Pa
ge 20 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

13-22

Mounting bracket for generator, power
steering pump and viscous fan,
removing and installing


Lock carrier in service position Page 13
-1

Removing

CAUTION!

Before disconnecting the battery, determine
the correct coding for the anti-theft radio.

Note:
Ribbed belt for A/C remains installed.
Ribbed belt, removing Page 13
-15
. - Switch ignition off and disconnect battery Ground (GND) strap.
- Remove ribbed belt and ribbed belt tensioner Page 13
-18
.
- Remove belt pulley for power steering pump.
- Unbolt power steering pump from mounting bracket for generator,
power steering pump and viscous fan and tie to side.
All lines remain connected
Pa
ge 24 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

13-23

- Follow procedures for "Coolant pump, removing
and installing" Page 19
-13
.

Note:
Coolant pump is bolted to mounting bracket for
generator, power steering pump and viscous fan.

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

- Replace O-ring for coolant pump (to guard
against leakage).

Tightening torques

Component

Tightening
torque
Belt pulley to power steering
pump 25 Nm (18 ft
lb)
Power steering pump to mounting
bracket for generator, power
steering pump and viscous fan
25 Nm (18 ft
lb)
Pa
ge 25 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