A4 2.5TDi Cam Belt Broken

[Dozz]

Would I be right in thinking all belts are made from the same stuff? The only reason I ask is because my 3.0 Lt v6 petrol has to do 80,000 miles before needing a cambelt. Now I can understand some engines work there belts harder and so need them replaced earlier but on time scale according to Audi my belt will last 8 years which is twice as long as what your quoting for the oil burners. Just another piece of info I had a passat 130 pd. The cambelt had gone by the service by 8k miles and I started to get nervous so had it done which turned out to be blessing. The belt had started to split not across but around the length of the belt you could put your finger through it at one point. I was also surprised at the width of the belt but I put that down to the work the camshaft has to do with the injectors

[adamss24]

Funny you should mention timming chains, they seem to be making a comeback, including VW.

VW are not the only manufacturer to change there recommendations for timing belt changes, I know Fiat/Alfa have halve all there milage rcomendation and time intervals. some of there car are down to 30k before a change

I think they just had to many warrantyclaims for broken cambelts, so the obvous thing was to shorten the recommended life. But i agree with the amount the dealers charge to change them are outragous.

Fact is, most of the timing belts break AFTER they are replaced, due to impropper tensioning of the belt tensioners or poor quality materials used. If its done by the factory, its ussualy changed after 80000 miles. Thats what is stated on the sticker under the bonet ! I do my own timing belts on my a4 v6 Tdi quattro and the belt takes only 20 min ! Its untill you get to it that takes another 40min-1.5 hours...

[Quattro25]

Fact is, most of the timing belts break AFTER they are replaced, due to impropper tensioning of the belt tensioners or poor quality materials used. If its done by the factory, its ussualy changed after 80000 miles. Thats what is stated on the sticker under the bonet ! I do my own timing belts on my a4 v6 Tdi quattro and the belt takes only 20 min ! Its untill you get to it that takes another 40min-1.5 hours...

Could you give any tips as to how to do this....I've bought all the VAG Tools for cam locking, pump locking, crank locking etc....

[adamss24]

You have to remove all the front components: bumper, radiator , cross member, headlights, front lock carrier, the AC belt, tha auxiliary belt(make a note as how it is routed, so you dont scratch your head how it goes !), then the viscous fan needs to come off- you will need 2 big adjustable spaners for that, because i forgot the sizes !- remove the fan pulley hold with 3x 10 mm bolts, then the timing belt covers vill have to come off. Now with a small brush and some bright colour paint, mark all the pulleys and the covers by placing dots on both the housing and the camshafts/crankshaft and fuel pump. Please note the pump timing is done in two stages: first you set the belt(remember to mark the position of the bolts by marking them with a felt pen/permanent marker), then dinamically-with the aid of the "tdi timing" plug-in of vag com ! Then the pump belt tensioner have to be undone( You will need a special 22 mm deep socket with a slot on the side or a ring spaner will do just fine, and a 7mm allen key to undo the tensioner. Discard it only if it shows signs of wear, then remove the belt then the tensioner holding braket will have to come off as well. Do not turn the engine while you remove the belts. Now with the 7mm allen key, undo the pressure of the automatic belt tensioner(anticlockwise !) and insert the spring clamp trough the slots to hold it back or you could use a 3mm drill bit as well ! Then move to the other tensioner and undo the holding nut just a bit then release the pressure by turning the tensioner with the allen key anticlockwise. I found that its easyer to remove the left hand side camshaft pulley with a 2/3 jaw bearing press, because the new belt will just not slide past the lip or you could remove the tensioner all toghether, but be carefull not to cross the threads as the bolt will stay at an odd angle. Now remove the water pump and discard it, clean the matting faces then fit the new one and dont overtighten the bolts. Refit all the components in order off removal and use new tensioners/rollers..If the cams move when you fit the belt, do not worry as the paint marks will hellp lining them back but you will need help from a mate to hold the sprockets ! Do not turn any pulley/cam/crank while you fit the belt and then tension the belt tensioners so there is no slack but not over tighten ! Remove the spring clip/drill bit from the automatic belt tensioner and tighten the tensioner as well. Refit the pump belt tensioner braket and fit a new tensioner only if it shows signs of wear or if you really loaded ! Fit the pump making shure all the marks/dots of paint line up then tension the pump tensioner then refit all the components in the order you removed. PLEASE TURN THE ENGINE AT LEAST 5-6 TURNS AND CHECK IF IT TURNS WITHOUT ANY PROBLEM. Refill the cooling system with fresh pink antifreeze and if everything is ok you could start the engine. Bleed the cooling system and check there are no leaks from the new water pump you fitted ! That's it. I advise against drinking while you do a timing belt job because there are things that will get overlooked but as soon as you done and everithing seems ok, crack few beers open and congratulate yourself for a job weell done ! Will post few images and tightening torques as soon as i find some time ! Please, if someone does one of these jobs, have a digital camera and take as many pictures as possible and you could add to my write-up as all i have wrote here is from memory and my english isnt as good as i wished to be ! Hope this helps. Use common sense and use a good quality belt kit like Contitech or Dayco-Pirelly or even one from the dealer if moneys is no problem, as its better safe than sorry ! Good luck to everyone who's going to tackle a job like this !

[Quattro25]

Thanks....

Sorry you had to type so much......I'm going to try in the next few days....