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Important note
Audi A3 (97-03) 1,9D TD11996-03
Engine code: AGR
Check For Engine Damage
Replacement Interval Guide
Repaii Times â€Ã³ lus
Special Tools
Special Precautions
Removal
Installation
IMPORTANT: Timing belt width must not he less than 22 mm.
1. Ensure crankshaft at TDC on No.1 cylinder. Ensure flywheel timing marks aligned [2].
2. Ensure camshaft setting bar fitted correctly [3].
3. Ensure locking pin located correctly in injection pump [4].
4. Hold camshaft sprocket. Use tool No.3036. Slacken bolt 1/2 turn [13].
5. Loosen sprocket from taper using a drift through hole in timing belt rear cover. Ensure sprocket can turn on taper.
NOTE: DO NOT use setting hat to hold camshaft when slackening sprocket holt.
6. Turn injection pump sprocket fully clockwise until bolts at end of slotted holes.
7. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
8. Turn automatic tensioner pulley clockwise until notch and raised mark on tensioner aligned [14]. Use wrench Matra V.159.
9. Tighten tensioner nut to 20 Nm [6].
10. Ensure flywheel timing marks aligned [2].
11. Hold camshaft sprocket. Use tool No.3036. Tighten bolt to 45 Nm [13].
12. Fit new injection pump sprocket bolts [5]. Tightening torque: 20 Nm +90°.
13. Remove:
o Injection pump locking pin [4]. o Camshaft setting bar [3].
14. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.
15. Ensure flywheel timing marks aligned [2].
16. Ensure locking pin can be inserted in injection pump [4].
17. If not: Slacken injection pump sprocket bolts [5]. Turn sprocket hub until locking pin can be inserted. Tighten bolts [5]. Tightening torque: 20 Nm +90°
18. Install components in reverse order of removal.
19. Tighten crankshaft pulley bolts [9]. Tightening torque: 10 Nm + 90°.
20. Fit and align RH engine mounting:
o Engine mounting clearance: 13 mm [18].
o Ensure engine mounting bolts [17] aligned with edge of mounting [19].
21. Tighten:
o Engine mounting bracket bolts [7]. Tightening torque: 45 Nm.
_o Engine mounting bolts 1151 Tightening torque: 50 Nm_
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