Cam Pullly removal - ?? tools & or techniques

[<isham-research.freeserve.co.uk@pop.pol.net.uk>]

> Any help full hints or tips re: removal of the cam belt pulley?  Any special
> do's and do NOTs?

> Do you need a special tool(s) or can the pulley be "worried" off the
> camshaft after the camshaft bolt & large washer are taken off?

The bolt is 80Nm.  The method given in the microfiche and Bentley doesn't
work.  The service tool is VAG 3036 - a long bar with a semi-circular
section welded to the end and two robust pins to engage the wheel.
It's made by Matra in Frankfurt.

Don't try and hold the 3036.  Put it on from _below_ and jam the end
up against the post on the alternator mounting bracket used for the
VAG 3084 tool.  I also have a 3/8" drive 19mm Crowfoot wrench and
a special insert for the end of the torque wrench - it's _very_ hard
to get a standard socket and torque wrench onto the bolt in many cars
because the clearance is so small.

With the tool, removal takes less than a minute.  An alternative way is
to jam a thick pin drift through the cam wheel and the opening in the
backing plate.  Make sure you use something that's as tight a fit as
possible, or you'll tear the backing plate.

A long high-quality open ended 19mm wrench is ideal for shifting the
bolt.  On some cars, a stepped ring (box) wrench just won't go on.

The pulley just 'wiggles' off, but the Woodruff key has a nasty habit
of dropping out.  Note the orientation of the inscriptions on the
wheel before taking it off - Audi's documents say the writing always
faces the engine, but this is wrong on some cars.

--
 Phil Payne
 UK Audi quattro Owners Club
 Phone +44 7785 302803  Fax +44 870 0883933