Genuine 1994 Audi 100 Belt Tensioner

1994 Audi 100 Belt Tensioner Parts and Q&A

• Q: How to remove and refit the timing belt tensioner and associated components for 5-cylinder diesel engines on 1994 Audi 100?

  A: To take off the tensioner of the timing belt, first of all, disconnect the battery negative lead, use the handbrake, jack up the front of a vehicle, and place it on the axle stands. Take the undershield out under the engine compartment and disconnect the front retaining lug, the front bumper, and the two front headlights. In models that have the AAT engine, eliminate the small air duct between the air cleaner and the intercooler. Loose the cable by removing the bonnet lock, unbolting the crossmember to the engine compartment side panels and front supports and remove it with the small air duct at the top of the radiator. Unscrew radiator upper mounting bolts, and then take off the brackets, but leave the hoses connected. Disconnect the radiator and the supports, push the right-hand side away to give the working room, and detach the auxiliary drivebelt and viscous fan unit. Unscrew and disassemble the auxiliary drivebelt tensioner, then turn the crankshaft to align the TDC, making sure that the TDC indicators on the flywheel and the fuel injection pump are in alignment. On earlier year models, loosen the timing belt tensioner bolt, turn clockwise to relieve tension and loosen the tensioner bolt with the next step which is to turn the tensioner bolt anticlockwise; in later models opposite applies. Lift the bolt and pull the tensioner out of the block of the cylinder and in case difficulty arises with the later type automatic tensioner, lack of clearance, take the vibration damper out. In refitting, simply attach the tensioner and bolt, but not tight enough so the tensioner plate may connect with the pin on the rear cover in the later models, and then refit and tension the timing belt. In case the vibration damper were taken off, refit it, the auxiliary drivebelt tensioner and drivebelt, viscous fan unit, radiator, bonnet lock cable, crossmember, small air duct, headlights, and front bumper. Lastly, reattach the undershield, lower the vehicle and reattach the battery. In the case of the camshaft front sprocker, follow the same steps that were used during the first process of disconnection of the battery, jacking the vehicle and removing the required parts. Unscrew the tensioner of the timing belt, take out the timing belt off the camshaft sprocket and take out the camshaft cover. Unscrew the bolt holding the camshaft sprocket in place, and slightly tap the sprocket off the camshaft. To refit, follow these steps: clean the mating surfaces, position the sprocket on the camshaft, position the retaining bolt and hand tighten. Refit and tension the timing belt, camshaft cover, auxiliary drivebelt tensioner and drivebelt, viscous fan unit, radiator, bonnet lock cable, crossmember, headlights, and front bumper and then lower the vehicle back and reconnect the battery. In the case of the rear sprocker of the camshaft, it is necessary to disassemble the fuel injection pump drivebelt, keep the rear sprocker still, loosen the bolt, and extract the sprocker. To refit, find the sprocket on the camshaft, and put the bolt loosely in, then refit the fuel injection pump drivebelt and follow the procedure of the injection pump timing. When working with the crankshaft sprocket, take off timing belt, push the crankshaft sprocket off the crankshaft and clean the surfaces joining. In the case of refitting, make sure that the sprocket is hooked on the crankshaft recess, tap it where needed, and reinstall the timing belt.