Genuine 1987 Audi 4000 Timing Belt

1987 Audi 4000 Timing Belt Parts and Q&A

• Q: How to remove and refit the Crankshaft Timing Gear and Timing Belt for Four-cylinder engines on 1987 Audi 4000?

  A: To begin, disconnect the battery negative lead if the engine remains in the car, then remove the alternator drivebelt. Unscrew the nuts to lift off the upper timing cover, using an Allen key as needed, and unbolt the pulley from the water pump. Next, turn the engine using a socket on the crankshaft pulley bolt until the piston in No 1 cylinder is at TDC on its compression stroke, ensuring the notch in the crankshaft pulley aligns with the arrow on the lower timing cover and both No 1 cylinder valves are closed. If necessary, loosen the centre bolt of the crankshaft gear, holding the crankshaft stationary with a wide-bladed screwdriver or by engaging top gear and applying the handbrake. With the TDC marks aligned, unbolt the crankshaft pulley from the gear and remove the lower timing cover. Loosen the nut on the timing belt tensioner and rotate the eccentric hub anti-clockwise to release the belt tension, then remove the timing belt from the crankshaft, camshaft, intermediate gears, and tensioner. Unscrew the nut to remove the timing belt tensioner, then unscrew the centre bolt and withdraw the intermediate gear, removing the Woodruff key while holding the gear stationary. Proceed to remove the crankshaft gear by unscrewing the centre bolt and withdrawing it, also removing its Woodruff key. Unscrew the centre bolt from the camshaft gear while holding it stationary, then withdraw the gear and remove the Woodruff key. Unbolt and remove the rear timing cover along with the alternator mounting bracket from the block and cylinder head. Start refitting by locating the alternator mounting bracket and rear timing cover on the engine, tightening the bolts. Locate the Woodruff key and camshaft gear on the camshaft, insert the centre bolt and washer, and tighten it. Similarly, locate the Woodruff key and crankshaft gear on the crankshaft, coat the threads of the centre bolt with a liquid locking agent, insert the bolt with its washer, and tighten it while holding the crankshaft stationary. Locate the Woodruff key and intermediate gear on the intermediate shaft, insert the centre bolt and washer, and tighten it. Refit the timing belt tensioner and fit the nut finger tight, ensuring the notch on the rear of the camshaft gear aligns with the top of the timing belt rear cover. Temporarily fit the crankshaft pulley to the gear, and with No 1 piston at TDC, turn the intermediate gear to align the indentation with the notch in the pulley. Locate the timing belt on the gears and tensioner, turning the tensioner clockwise to pretension the timing belt while checking that the TDC marks remain correctly aligned. Turn the tensioner clockwise until the timing belt can just be twisted 90° with the thumb and index finger midway between the camshaft and intermediate gears, then tighten the nut to secure the tensioner. Remove the crankshaft pulley, fit the lower timing cover, and tighten the bolts, followed by refitting the crankshaft pulley and tightening the bolts. Finally, locate the pulley on the water pump and tighten the bolts, refit the upper timing cover and tighten the nuts, then reinstall the alternator drivebelt and reconnect the battery negative lead as necessary.