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FOREWORD. |
STEP 1. |
Replacing Cam
Belt – 1998 Audi A3 1.8T (Engine Code AGU)
Here is the procedure for replacing the cam (or
timing) belt for the above vehicle.
You will need the following parts:
1. New timing belt
2. Updated timing belt tensioner (part no. 06B
109 477)
3. Updated timing belt pulley (part no. 06B 109
243)
Some torque wrench settings:
Bottom and middle cam belt covers to engine -
10Nm (use thread locking compound)
Vibration damper/crank pulley to crank - 40Nm
Engine support to cylinder block - 45Nm |

Firstly the
vehicle must be jacked up and the front right
hand wheel removed.
Remove the engine cover by turning the fasteners
indicated, anticlockwise by 90 degrees. Lift off
cover
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STEP 2. |
STEP 3. |

Remove the pipes
and electrical connectors indicated by the red
arrows and then undo the bolts marked by the
green arrows. You should now be able to lift the
coolant expansion tank, pipes and power steering
reservoir (black container with green top) out
of the way). But throughout you may need to
temporarily place them back to access certain
components. |

We now need to
remove the ribbed belt that drives the
alternator, power steering pump and air
conditioning compressor.
To do this, attach a spanner on the lug of the
ribbed belt tensioner and rotate it clockwise as
shown by the red arrow. There are holes in the
tensioner lug and body to place a thin dowel
that holds the tension off the belt. I used a
small allen key shown by the green arrow. |
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STEP 4. |
STEP 5. |

Now remove the
ribbed belt, but be sure to mark the direction
of rotation so that it is replaced in the same
way. If used belt is fitted the wrong way round
it can cause it to break. |

Now undo the four
bolts that hold the ribbed belt tensioner to the
engine and remove it completely. |
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STEP 6. |
STEP 7. |

Unclip the
fasteners for the top plastic cam cover. I was
unable to remove it as the engine mount appeared
to be in the way, but it is required to gain
access to the cam sprocket so the timing mark
can be viewed.
Next undo the two jubilee clips for the metal
turbo to intercooler pipe and the bolt that
holds the pipe to the car body. Remove the pipe. |

Undo the clips and
screws for the engine sound insulation plates
underneath the car and on the right wheel arch.
Remove these plates. |
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STEP 8. |
STEP 9. |

Remove the
crankshaft vibration damper/ribbed belt pulley
by undoing the four allen headed bolts.
Do this by holding the centre of the pulley with
a 12 point 19mm socket whilst undoing the allen
bolts. Remove the pulley. |

Remove the rubber
plug from the top of the gearbox and turn the
central 19mm bolt clockwise until the engine is
at top dead centre (TDC). There is a mark on the
flywheel that can be viewed through a hole in
the top of the gearbox. |
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STEP 10. |
STEP 11. |

The camshaft
sprocket timing mark should line up with the
mark on the cam cover (ignore the second white
mark on the right of the pulley in the picture). |

Now using a jack,
support the engine under the sump and remove the
six bolts for the engine mount console that
holds the engine to the right hand chassis leg,
marked by the red arrows. Remove the engine
mount from the car. |
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STEP 12. |
STEP 13. |

Now remove the
three bolts that hold the other part of the
mount to the engine. |

To remove the left
hand bolt the engine needs to be jacked up a
small amount. To remove the bottom bolt, the
engine needs to be lowered a small amount. |
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STEP 14. |
EXPLODED DIAGRAM. |

I found this part
of the mount very awkward and I was unable to
remove it from the car, so I just left it
hanging. It does need to be unbolted though, to
gain access to the timing belt components.
Undo the five bolts holding the middle and
bottom cam covers and remove the covers. Note,
when replacing these bolts you need to use
locking compound on the threads as they are not
done up particularly tight. |

Here is an
exploded diagram of the timing belt components
for clarity. |
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STEP 15. |
ADDED TIP. |

BTW, you should
now have enough room to remove the upper plastic
timing cover.
Before the timing belt itself can be removed,
the tension on the belt has to be slackened.
There are two ways to do this. I personally
removed the bolts in the sequence below. Idler
pulley bolt (red arrow), then tensioner
fastening bolts (green arrows) and then finally
the tensioner pulley retaining bolt (blue
arrow). |

I later found out
that Audi mechanics slacken the tension by
inserting a bolt through the brass coloured
section on the pulley into the tensioner body
and then inserting a pin to hold the tensioner
piston. The bolt position is indicated by the
yellow screwdriver in the picture below.
The choice is yours, either way works well. |
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UPDATED PARTS. |
STEP 16. |

I was surprised to
find that my car was fitted with the updated
tensioner and pulley already. I expected the
earlier version on a 1998 car. The parts were
definitely original, maybe I’ve just been
misinformed as to what year vehicles were fitted
with the older parts.
See picture above, new parts on the bottom. Note
the pin in the new tensioner holding the piston
in. |

Before removing the old timing belt it is a
good idea to mark the belt with the cam sprocket
and also the belt with the crank sprocket.
When the belt is removed, count the number of
teeth between the two marks and then mark the
new belt in the same places. When you come to
fit the new belt, simply line these marks up
with those on the sprockets and you know that
the cam timing will be fine. This is only true
if the sprockets are not turned whilst the belt
is off. In fact you can replace a belt in this
way and not worry about setting the engine to
TDC (but it is not recommended).
To replace the belt, I found it easier to fit it
to the crank sprocket first, then the water pump
and then the cam sprocket.
Next install the tensioning pulley, and then the
finally the tensioner itself. When you are
confident that the belt is installed correctly,
pull out the pin on the tensioner. |
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STEP 17. |
The marks on the
flywheel to gearbox and cam sprocket to cam
cover should still be aligned.
Now carefully rotate the engine via the crank
sprocket a few complete turns. If you sense any
sudden resistance STOP IMMEDIATELY and recheck
your timing marks. You will feel compression
pressure, but should not feel sudden resistance
as this would be a valve hitting a piston….not
good!!
Unfortunately resetting the timing at this point
would require the removal of the tensioner and
pulley again, and you would need to press the
piston of the tensioner back into the body and
reinsert the pin. So my advice it to check and
double check so you get the timing right first
time!!
Well hopefully by this point you should have the
new timing belt fitted. Well done! Now you just
got to get all those parts you’ve removed back
on the engine. I hope you remember where
everything went!!
Remember, take your time and this should be a
very straight forward procedure. |