Auxiliary belt tensioner replace - 2004 Audi A4

You didn't say if you mean the auto tensioner of the auxiliary belt. Assuming this is so, I don't know but just wanted to mention not all vehicles use an auto tensioner and a significant number have to be manually adjusted.

Auxiliary belt adjusters have been increasingly deleted over the last decade or so - replaced by a stretchy belt. These belts can be removed and refitted but they are a struggle.
Recommendation is they are cut off when removal is necessary and replaced with new - a tool to aid fitting is supplied with a new belt.

which belt?
timing belt or auxiliary belt

if auxiliary (Fan / alternator / aircon) belt then there is a tensioner.
lever it to release / instal the belt

you have to have serpentine belt tool kit. and do not have to buy one unless you want one, most auto parts have loaner tools you have to have a credit card to secure the cost of replace in case you loose a part or you do not return it, then they charge your credit.

you need that tool to release the tension on the belt, it is not possible to not do without that tool, i tried doing that i tried for 5-6 hours without any luck. i went down to auto store got the tool and we got done in 15 minutes.
take it from me it not worth all that waist of time and energy just get the tool. its fast and simple.

thank you rod

Here is a Diy guide to adding tension to your auxiliary belt, If your not confident, it's best to allow a qualified mechanic to do the task as if your dont have the correct tension, other problems could accuor and make the car un-driveable as it's likely the belt controls your cooling system too.

http://www.ehow.co.uk/how_7442911_adjust-alternator-belt-tension-gauge.html

Time to replace the pulley, you can test it by pulling off the belt and spinning the pully with your hand or some compressed air, if it makes noise then its time to replace.

1. Place a wrenchon the tensiorer pulley bolt and rotate the tensioner body until tenion on the belt is relieved.
2. Remove the belt from the auxiliary components and carefully release the tensioner.
3. Route the new belt over the various pulleys, again rotating the tensioner to allow the belt to be installed, then release the belt tensioner. Make sure the belt fits properly into the pulley grooves - it must be completely engaged.
Good Luck

It will be necessary to replace the belt before it breaks and leaves you stranded. Good Luck! I hope you find this to be very helpful!

Disconnect battery earth lead. Do not turn crankshaft or camshaft whn timing beld removed. Remove spark plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated) Do not turn engine via camshaft or other sprockets. Observe all tightening torques. Remove engine, remve RH engine mounting. Remove auxiliary drive belts, water pump pulley, crankshaft pulley, timing belt upper cover, timing belt lower cover. Turn crankshaft clockwise to TDC on No. 1 cylinder, slacken tensioner bolts 5 & 6. Move tensioner away from belt and lightly tighten bolts. Remove timing belt. Remove water pump and replace with new one. Suggest to replace cambelt as well.
Installation
Ensure timing marks aligned3 & 4. Fit timing belt in anti-clockwise direction, standing at crankshaft sprocket. Ensure belt is taut between sprockets on non-tensioned side. Slacken tensioner bolt 5. slacken tensioner bolt 6. Allow tensioner to operate. Tighten tensioner bolt 6. Tighten tensioner bolt 5. Turn crankshaft on turn clockwise. Ensure crankshaft sprocket timing marks aligned 4.
Slacken tensioner bolt 5. Slacken tensioner bolt 6. Allow tensioner to operate. Tighten tensioner 6. Tighten torque: 20 - 26 Nm. Tighten tensioner bolt 5. tighten torque: 20 - 26 Nm. Apply thumb pressure to belt at middle. Approximately 5kg. Belt should deflect to 1/4 of tensioner bolt head width 7. Belt tention can also be set using burroghs (BT-33-73F) tension gauge 10 at middle. Turn crankshaft 90 ° anti clockwise. Check belt tension is 9.5 16,5kg (engine must be cold). Install components in reverse order of removal. Fit cranckshaft pully. Tighten crankshaft pully bolts 8. G4-J: Tightening torque: 12-15Nm.
G4-N/G4-k: Tightening torque: 10-12Nm
G4EA: Tighten crankshaft pully bolt 9. Tighten torque: 140-150Nm.

Preparation

Caution! Remove the ignition key.

Remove
the screw holding the engine stabilizer brace to the bracket on the engine
the screws holding the engine stabilizer brace to the suspension turrets
the engine stabilizer brace.

Applies only to B6xx4T engines:
Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and turbocharger (TC). Put them to one side. Remove the clamp from the intake manifold for the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the pipe towards the firewall.

Relieve the load from the belt tensioner.
Remove the auxiliaries belt. See: Drive Belt\Service and Repair
Remove the upper timing belt cover.
Remove the front timing belt cover.
Lift up the servo reservoir and place it on top of the engine.Note! Ensure that the oil does not leak from the ventilation hole in the filler cap.

Seal the hose between the expansion tank and the radiator.
Disconnect the hose at the tank.
Lift up the expansion tank and place it on top of engine.

Raise the car. Remove
the right front wheel
the plastic nuts on the cover in the fender liner. Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulleys correspond.
Turn the crankshaft a further 1/4 turn clockwise. Then turn back counter-clockwise until the markings correspond.
Remove the upper timing belt cover.

Remove the 4 vibration damper screws. Counterhold the crankshaft central nut.

Remove
the vibration damper
the auxiliaries belt
the belt cover behind the crankshaft pulley for the auxiliaries belt. Spray universal oil or similar around the rubber sleeve on the underside of the oil pump.

Remove the rubber sleeve.

Removing the timing belt

Slacken off the belt tensioner
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw still.
Turn the tensioner eccentric counter-clockwise using a 6 mm Allen key.
Turn to 10 o'clock.
Unhook and remove the timing belt.Caution! Do not turn the camshafts or the crankshaft when the timing belt has been removed.


Checking the tensioner pulley and idler pulley Check bearing wear:
Spin the idler pulley and listen for noise. If replacing with a new idler pulley, tighten to 24 Nm .
Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw.
Screw in the center screw by hand.
Ensure that the tensioner fork is centered over the cylinder block rib / bracket.
Ensure that the Allen hole on the eccentric is at "10 o'clock".

Installing the timing belt

Install the belt in the following order:
crankshaft
the idler pulley
intake cam
exhaust cam
water pump
tension pulley.Note! The variable valve timing unit on B6304S engines does not have a return spring. The unit is easily dislodged when reinstalling the timing belt.


Tensioning the timing belt

This adjustment is carried out on a cold engine. A suitable temperature is approximately 20°C / 68°F .
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be in tension between the intake camshaft pulley, the idler pulley and the crankshaft.
Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window.
Hold the eccentric secure. Tighten the center screw to 25 Nm .
Check that the indicator is in the correct position.

Check

Press the belt to check that the indicator on the tensioner moves easily.
Install the upper timing belt cover. Turn the crankshaft 2 turns. Check that the markings on the crankshaft and camshaft pulley correspond.
Check that the indicator on the belt tensioner is within the marked area.

Finishing

Install the auxiliaries belt around the pulley on the crankshaft.
Install
the rubber sleeve on the underside of the oil pump
the vibration damper.
Use new screws.
Tighten to 35 Nm .
Angle-tighten 50°.
Use the crankshaft center nut as a counterhold
the plastic nuts for the cover in the right-hand fender liner
the right front wheel.

Lower the car.
the front timing belt cover. Tension the auxiliaries belt.
the expansion tank
the hose between the expansion tank and the radiator. Remove the lock grip pliers
the servo reservoir
the upper timing belt cover.

Applies only to B6xx4T engines:
Twist the intake pipe for the turbocharger for cylinders 1, 2 and 3 into position.
Tighten the clamp.
Install the plastic hoses between the turbocharger (TC) and the charge air cooler and between the air cleaner (ACL) and the turbocharger (TC). Tighten the hose clamps.

the engine stabilizer brace. Tighten to 50 Nm
the screw holding the engine stabilizer brace to the bracket on the engine. Tighten to 80 Nm .

Final check
Check and top up if required
coolant level
the servo fluid level. Test drive the engine.

Don't forget to rate the solution

thanks
good luck