Timing belt tips: Audi A3 1.8T
Significant errors frequently happen when changing the timing belt. To ensure that the belt change operation goes smoothly, the ContiTech Power Transmission Group provides fitters with a detailed installation guide; here is a step-by-step explanation of how to change the belt correctly in an Audi A3 1.8T with engine code ARZ.
The manufacturer recommends changing the timing belt and the tensioning pulley at 180,000km or after five years, and the labour time is 2.2 hours. Tip: The multi-V belt ought to be changed at the same time as the timing belt. The multi-V belt has the same change interval as the timing belt. It is essential, therefore, to change the multi-V belt as part of the package in order to avoid later failures with unnecessary costs.
Fitters need the following special tools for the procedure: 1. OE locking tool (T40011). 2. OE tensioning bolt (T10092). 3. OE engine support bridge
(10-222A).
Preparatory work
Identify the vehicle using the engine code.
Disconnect the vehicle battery. Do not turn the crankshaft and camshaft once the timing belt has been removed. Turn the engine in the normal direction of rotation (clockwise) unless otherwise specified.
Turn the engine only at the crankshaft pulley and not at other sprockets.
Comply with all the vehicle manufacturer’s tightening torques. Raise the vehicle and support the engine or fit the engine support bridge so that the front engine mount is not under strain.
Removal: remove engine cover, power steering reservoir (do not detach hoses), ancillary unit belt and belt tensioner, coolant expansion reservoir (hoses do not need to be detached), upper, middle and lower timing belt guards; disconnect fuel lines; remove plug from Hall-effect sensor, hose between charge-air line and charge-air cooler, engine compartment under-panel, crankshaft belt pulley and front engine mount, supporting engine to do so or lifting engine with engine support bridge.
Removal
– camshaft belt 1. Set valve timings to TDC mark of
cylinder 1. 2. Mark (notch) on camshaft pulley must align with mark (notch) on rear timing belt guard. 3. Check crankshaft mark. To do so, remove rubber plug from torque converter housing. Mark (notch) on flywheel must align with mark (projection) of opening. 4. Screw OE tensioning bolt (T10092) into hydraulic damper and slowly release tension on timing belt/ tensioning pulley by turning OE tensioning bolt (T10092), until OE locking tool (T40011) can be inserted into small bore of hydraulic damper. 5. Timing belt can now be removed.
Installation – camshaft belt
1. Screw OE tensioning bolt (T10092)
into new hydraulic damper. 2. Fit new tensioning pulley (27Nm) and new hydraulic damper (15Nm) and tighten OE tensioning bolt (T10092) such that locking tool will be easy to remove later from new hydraulic damper (Fig. 12). Do not withdraw locking pin until timing belt and tensioning pulley are correctly installed! Hydraulic damper may only be actuated with tensioning
bolt. Pressing together with vice or pliers could damage hydraulic damper. 3. Fit timing belt on crankshaft pulley, starting clockwise. Take care to ensure that timing belt is not kinked during fitting! Timing belt must be tight between sprockets on tight side. 4. Tension timing belt by withdrawing locking pin of hydraulic damper and removing OE tensioning bolt (T10092). Tension is set by hydraulic damper. There are no other marks on tensioning pulley. 5. Turn engine through two revolutions in direction of engine travel. Set engine to TDC of cylinder 1. Check and, if necessary, correct timings. 6. Refit crankshaft belt pulley. To do so, hold crankshaft central bolt using box-end wrench or counterhold, then tighten to appropriate torque (strength category M8 8.8, 10Nm +90deg., M8 10.9, 40Nm). 7. Fit components in reverse order of removal.
Fitting
Upper and lower timing belt guard (10Nm) using thread locker, ancillary unit belt and belt tensioner (23Nm). Engine mount bolts and engine mount (engine stay to cylinder block 45Nm, connecting stay to body/engine mount 25Nm, engine mount to body 40Nm +90deg. use new bolt).
Hose between charge-air pipe and charge-air cooler, power steering reservoir and coolant expansion reservoir, reconnect fuel lines and plug Hall-effect sensor back in. Refit engine cover and engine compartment under-panel. 8. Record changing of original ContiTech timing belt on sticker supplied and stick this in engine compartment. Then carry out a test run or test drive.
Get it on-line
Under the name Technical Instructions, the ContiTech Power Transmission Group is offering comprehensive fitting instructions for its power transmission belts on more and more product pages in the Product Information Centre (PIC).
The online documents serve as digital product inserts which are always absolutely up to date. The offering is aimed specifically at workshops which install ContiTech products. The company provides the fitting instructions in 16 languages.
ContiTech is expanding its library of technical Instructions on an on-going basis, and the number of available documents will have risen to almost 200 by the end of the year. The aim is to offer dedicated fitting instructions for all the current belts and kits. In addition to the applications and engines, they also contain a detailed parts list (illustrated in some cases), tips on any special tools required and step-by-step instructions for removal and fitting.
Automotive professionals can enter the article number of the product they are looking for at www.contitech.de/pic, which will lead them to the specific product page. Those with a smartphone can also access the page in the PIC directly via the QR code on the packaging. The fitting instructions are available for download under the tab “Mounting the belt”.