How to Replace timing belt on Audi A6 quattro 3.0D TDi 2005

Audi A6 quattro 3.0D TDi 2005 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Camshaft sprocket holding tool – No.3036.
• Camshaft sprocket puller – No.3032.
• Crankshaft turning tool – No.T40058.

Special precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow 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.

Repair times – hrs

Camshaft drive belt/chain – R & I	15,00
Camshaft drive belt/chain, AT – R & I	13,10
Camshaft drive belt/chain (rear) – R & I	13,10
Injection pump drive belt/chain – R & I	1,60

Valve timing procedures

Removal

NOTE: The high-pressure fuel pump fitted to this engine does not require timing.

1. Raise and support front of vehicle.
2. Remove:
   • Engine top cover.
   • Air intake pipes to inlet manifolds.
   • High-pressure fuel pump belt cover [1] .
3. Slacken tensioner pulley bolt two turns [2] .
4. Move tensioner pulley away from belt.
5. Hold camshaft sprocket [3] . Use tool No.3036.
6. Slacken camshaft sprocket bolt two turns [4] .
7. Loosen camshaft sprocket from taper [3] . Use tool No.3032.
8. Remove:
   • Camshaft sprocket puller.
   • Camshaft sprocket bolt [4] .
   • Camshaft sprocket together with high-pressure fuel pump belt [3] .

   NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: If reusing old belt, observe direction of rotation marks on belt.

1. 1. Ensure tensioner pulley hexagon at 6 o’clock position [5] .
   2. Ensure tensioner pulley retaining lug is properly engaged [6] .
   3. Lightly tighten tensioner pulley bolt [2] .
   4. Fit belt to high-pressure fuel pump sprocket [7] .
   5. Fit camshaft sprocket together with high-pressure fuel pump belt [3] .
   6. Fit camshaft sprocket bolt [4] .
   7. Ensure belt is taut on non-tensioned side.
   8. Tighten camshaft sprocket bolt finger tight [4] .
   9. Slacken tensioner pulley bolt [2] .
   10. Turn tensioner pulley anti-clockwise until hexagon at 1 o’clock position, then clockwise until hexagon at 3 o’clock position. Use Allen key [8] .
       NOTE: DO NOT allow hexagon to move up to or beyond 12 o’clock position.
   11. Turn tensioner pulley anti-clockwise until pointer aligned with notch [9] & [10] . Use Allen key [8] .
   12. Hold tensioner pulley in position. Use Allen key [8] .
   13. Tighten tensioner pulley bolt [2] . Tightening torque: 23 Nm.
   14. Hold camshaft sprocket [3] . Use tool No.3036.
   15. Tighten camshaft sprocket bolt [4] . Tightening torque: 75 Nm.
   16. Turn crankshaft one turn clockwise. Use tool No.T40058.
   17. Ensure tensioner pulley pointer and notch aligned [9] & [10] . If not: Repeat tensioning procedure.
   18. Fit high-pressure fuel pump belt cover [1] .
   19. Install components in reverse order of removal.