2.5L TDI AEL: A Benchmark for the OT Brand? With photo: Look.

Hello,

I'm still working on putting my AEL together (the one with the five-camshaft design).
/viewtopic.php?t=4753&postdays=0&postorder=asc&start=0

Now, it asks me: Where is the reference mark on the case for the OT marking, which can be seen on the toothed wheel through the viewing window?
http://people.freenet.de/kmrlange/OT_Markierung2.jpg
Unfortunately, I only see a large hole with a small marking .
The difference between the top and bottom is approximately plus or minus 2 degrees.
Sure, here is the translation of the text from German to English:

'Only where is the reference?'

Can anyone help?

Best regards, KAi.

Hi,

According to Etzold, the marking is present from model year 1994 onwards, and can be read on all AEL models by looking at a mirror located on the underside of the vibration damper at the front of the engine.

Hello,

My original repair manual doesn't provide that information. There's just a beautiful, impressive viewpoint.
without any reference brand displayed on the casing. According to the repair manual, the timing belt will be...
WITHOUT the shock absorber installed, and tightened. How am I supposed to do anything in that situation?
Reading vibration dampers while they are on the workbench????
Inability to understand is becoming widespread.
Where is the reference mark for the vibration damper on the engine block?


Best regards, KAi.

Is there a small triangle visible on the side, next to the round hole, with its tip pointing towards the flywheel?

Best regards, Rainer.

Hi,

no, look again

http://people.freenet.de/kmrlange/OT_Markierung3.jpg

The big hole is definitely the right one. The entire club is also into OT.
Anyway, the first piston protruded about four-tenths of an inch above the top of the block.
Since then, I haven't moved the car.

Rudi is puzzled...

Hi Kai, in the picture where you wrote 'Kerbe,' you can see a bright spot on the casing between 'Kerbe' and the red 'K.' Can you see the triangle on the transmission housing from the engine? If not, then simply mark a reference point on the transmission housing parallel to the notch, when the first cylinder is at top dead center (TDC).
Most five-cylinder engines have an 'O' on the flywheel, which, at Top Dead Center (TDC) of cylinder 1, is partially covered by the lower edge of the opening in the bell housing, where the notch you see is located.

Sure, here's the translation of the German text into English:

'Hai mersente' translates to 'You are welcome' or 'You're welcome' in English.

There is no triangle to be seen because there isn't one. Even making a small notch as a reference mark in the transmission bell housing can be useful, provided you have accurately aligned the top dead center (TDC). But... guys surely there should be a proper marking there???? Otherwise, I'm usually off by one or half a degree.

Best regards, Kai.

On older five-cylinder engines, you only have the marking on the vibration damper and the reference mark on the rear timing belt cover. You can only see that from below or by looking at it in a mirror.
You install the timing rotor, align it, and then tighten the vibration damper. Now, check that everything is at top dead center (TDC) and tighten the camshaft screw.

Hello mersente and christians,

You and Etzold (whoever the good one is ) are right. It's even written in the 'Help yourself' section. Whoever can read...
It's not included in the Audi repair manual for the AAT/AEL engines!!

Here are the pictures for those who are still interested.
http://people.freenet.de/kmrlange/OT_Marke_Schwingd.JPG http://people.freenet.de/kmrlange/OT_Motormarke_Referenz.JPG

Conclusion: I learned something new again!


Best regards, Kai.

kmrlange wrote:

Etzold (whoever that good person is )

The author of such a self-help book.

Hello,
I just replaced the timing belt, and since I had trouble with the markings, I marked the old timing belt. Now, the engine isn't running correctly, and I want to double-check everything. The last two pictures from 'kmrlange' are okay, but the ones of the clutch housing above are incorrect. The following is correct:
http://de.geocities.com/pcman701/netpic/PICT1895.JPG
The notch is located precisely on the horizontal edge of the hole at the top, directly below the fuel injection pump.
Okay, now to my problem: how does this look on the camshaft? The only marking I can find anywhere is on the drive wheel for the EP (electronic power steering). Where should it be positioned? What other types of margins are there?

Regards,
Mathias

Hi,
It's mentioned in kmrlange's thread about the five-piece camshaft (use the search function) or in a technical article.

Okay, so, my question isn't really answered yet. That's probably because I assumed there would be markings on the camshaft sprockets, like there are in other cars. Apparently, that's not the case. If I'm reading this correctly, the two camshaft sprockets can be rotated if they're not securely fastened. I haven't removed them yet, but is there no kind of locking mechanism? Therefore, there's no way to check if the crankshaft is at TDC (Top Dead Center) without using that mysterious alignment tool and removing the pump gear. The only marking that can still be considered a 'flute' is the one on the EP-wheel, but it doesn't align with the OT marking!?!
Did I understand that correctly?
I'm starting to believe that this car was designed by someone with half a brain. You just want to replace the timing belt, and you have to disassemble half the car to do it (not to mention that perverse crankshaft pulley bolt), and then you can't even check if you've done everything correctly. I think I'm going to buy another Japanese car; they have 2NWs with .

Regards,
Mathias

hi,

Okay, so my 5-cylinder engine has 4 timing marks... but it's also a 20V turbo. I'm actually surprised that the diesel engines don't have 3 (one is eliminated due to the two camshafts).

Hi Micha,

sat24 wrote:

Therefore, there is no way to check if the North West (NW) is aligned with Top Dead Center (OT) without using this mysterious alignment tool and disassembling the pump gear. The only marking that can still be considered a "flute" is the one on the EP-wheel, but it doesn't align with the OT marking!?! Did I understand that correctly?

Yes, unfortunately, that's the case.

Thank you for the clarification.
'Even though the engine sounds okay (I'm too afraid to test drive it), I have a question: Where is the timing mark on the fuel injection pump gear relative to the mark on the housing when the engine is at Top Dead Center (TDC)? I don't want to take anything apart yet, but I also can't imagine that I installed the belt one tooth off. However, that's the deviation that the ESP (Engine Control Unit) seems to be showing (I tried it once, and all the marks aligned when it was one tooth off).' Can a test damage the engine?

--edit on
I just tested one more tooth, but the engine didn't start. I moved one tooth back, and the thing runs. I don't understand it, but whatever, as long as it's running.
--edit off

Regards,
Mathias