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How to Replace timing belt on Audi A6 (C6) 2.0 TDI 2005-2008

Audi A6 (C6) 2.0 TDI 2005-2008 timing belt replacement instructionts . Full guide for cambelt change!

Replacement Interval Guide

  • Audi recommend:
  • Replace timing belt every 75,000 miles or 5 years.
  • A4 – up to VIN No.8E Z 5 A 400 000: Replace tensioner pulley every 75,000 miles.
  • A4 – from VIN No.8E Z 5 A 400 001: Replace tensioner pulley every 150,000 miles.
  • A6: Replace tensioner pulley every 150,000 miles.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Remove & install:
A4 2,60
AT +0,30
A6 3,50

Audi Timing Belt Tool

  • Auxiliary drive belt tensioner locking pin – Audi No.T10060A.
  • Camshaft sprocket holding tool – Audi No.T10172/2.
  • Camshaft sprocket locking tools – Audi No.3359.
  • Support guides – Audi No.3369.
  • Tensioner pulley locking pin – Audi No.T10115.
  • Two-pin wrench – Audi No.T10020.
  • Type A: Crankshaft sprocket locking tool – Audi No.T10050.
  • Type B: Crankshaft sprocket locking tool – Audi No.T10100.

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.
How to Replace timing belt on Audi A6 (C6) 2.0 TDI 2005-2008
How to Replace timing belt on Audi A6 (C6) 2.0 TDI 2005-2008

Removal

  1. Raise and support front of vehicle.
  2. Disconnect exhaust pipe for auxiliary heater (if fitted) from engine undershield.
  3. Remove:
      • Front wheels.
      • Engine undershield.
      • Front bumper cover.
      • A6: Headlamps.
  4. Disconnect:
      • Turbocharger/intercooler air hose(s) from bottom of front panel.
      • AC pipe from intercooler (if necessary).
      • Wiring harness from front panel near cooling fan (if necessary).
  5. Remove:
      • A4: Intercooler air duct.
      • Air intake pipe between front panel and air filter.
      • Front panel bolt (if necessary) [1] .
  6. Install support guides No.3369 in front panel [2] .
  7. Remove front panel bolts [3] & [4] .
  8. Slide front panel forward into service position.
  9. Refit upper rear bolts in front holes to steady front panel.
  10. Remove:
      • Engine top cover.
      • Auxiliary drive belt. Use tool No.T10060A.NOTE: Mark direction of rotation on belt with chalk if belt is to be used.
      • Crankshaft pulley centre cap.
      • Crankshaft pulley bolts [5] .
      • Crankshaft pulley [6] .
      • Timing belt upper cover [7] .
      • Timing belt centre cover [8] .
      • Timing belt lower cover [9] .
  11. Turn crankshaft clockwise to TDC on No.1 cylinder.
  12. Ensure window in each camshaft sprocket at 12 o’clock position [10] .
  13. Lock camshaft sprockets. Use tool Nos.3359 [11] & [12] .
  14. Lock crankshaft sprocket.NOTE: There are two types of crankshaft sprocket.
      • Type A: Use tool No.T10050 [A] .
      • Type B: Use tool No.T10100 [B] .

    NOTE: Ensure lug of crankshaft sprocket locking tool located in oil seal housing [13] .

  15. Ensure timing marks aligned [A] or [B] .
  16. Slacken bolts of each camshaft sprocket [14] & [15] .NOTE: Slacken bolts until sprockets can be moved within slotted holes.
  17. Hold tensioner pulley. Use tool No.T10020 [16] .
  18. Slacken tensioner pulley nut [17] .
  19. Turn tensioner pulley anti-clockwise until locking pin can be inserted. Use tool No.T10020 [16] .
  20. Insert locking pin in tensioner pulley [18] . Use tool No.T10115.
  21. Turn tensioner pulley fully clockwise until it reaches stop [19] . Use tool No.T10020.
  22. Lightly tighten tensioner pulley nut [17] .
  23. Remove timing belt, starting at water pump sprocket.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: Engine must be COLD.

  1. Ensure camshaft sprockets locked with tools [11] & [12] .
  2. Ensure crankshaft sprocket locking tool located correctly.
  3. Ensure timing marks aligned [A] or [B] .
  4. Ensure tensioner pulley locking pin inserted [18] . Tool No.T10115.
  5. Ensure tensioner retaining lug is properly engaged [20] .
  6. Turn camshaft sprockets fully clockwise in slotted holes.NOTE: Sprockets should turn freely without tilting.
  7. Fit timing belt in clockwise direction, starting at crankshaft sprocket.NOTE: If reusing old belt, observe direction of rotation marks on belt. Ensure belt is taut between sprockets on non-tensioned side.
  8. Remove locking pin from tensioner pulley [18] .
  9. Slacken tensioner pulley nut [17] .
  10. Turn tensioner pulley slowly clockwise until pointer aligned with notch [21] .NOTE: Ensure tensioner pulley nut does not turn [17] .
  11. Hold tensioner pulley. Use tool No.T10020 [16] .
  12. Tighten tensioner pulley nut [17] . Tightening torque: 20 Nm + 45°.NOTE: As tensioner pulley nut is tightened, the pointer may move clockwise 5 mm maximum. DO NOT adjust position of tensioner pulley. Timing belt will settle once run in.
  13. Hold camshaft sprocket (CA1). Use tool No.T10172/2.NOTE: Ensure belt is taut between sprockets on non-tensioned side.
  14. Tighten bolts of each camshaft sprocket [14] & [15] . Tightening torque: 25 Nm.
  15. Remove:
      • Camshaft sprocket holding tool.
      • Camshaft sprocket locking tools [11] & [12] .
      • Crankshaft sprocket locking tool [A] or [B] .
  16. Check valve timing as follows:
      • Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
      • Fit camshaft sprocket (CA1) locking tool while slowly turning crankshaft to TDC [11] . Tool No.3359.
      • Ensure camshaft sprocket (CA2) locking tool can be inserted [12] . Tool No.3359.
      • Ensure crankshaft sprocket locking tool can be inserted easily [A] or [B] .
      • Ensure timing marks aligned [A] or [B] .
      • Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch [21] .
  17. If camshaft sprocket (CA2) locking tool cannot be inserted [12] :
      • Slacken camshaft sprocket (CA2) bolts [15] .
      • Turn camshaft sprocket (CA2) hub until locking tool can be inserted [12] . Tool No.3359.
      • Hold camshaft sprocket (CA2). Use tool No.T10172/2.
      • Tighten camshaft sprocket (CA2) bolts [15] . Tightening torque: 25 Nm.
      • Remove camshaft sprocket holding tool.
      • Remove locking tools [11] , [12] , [A] or [B] .
      • Turn crankshaft two turns clockwise to TDC on No.1 cylinder.
      • Check valve timing.
  18. If crankshaft sprocket locking tool cannot be inserted [A] or [B] :
      • Slacken bolts of each camshaft sprocket [14] & [15] .
      • Turn crankshaft sprocket until locking tool can be inserted [A] or [B] .
      • Hold camshaft sprocket (CA1). Use tool No.T10172.
      • Tighten bolts of each camshaft sprocket [14] & [15] . Tightening torque: 25 Nm.
      • Remove camshaft sprocket holding tool.
      • Remove locking tools [11] , [12] & [A] or [B] .
      • Turn crankshaft two turns clockwise to TDC on No.1 cylinder.
      • Check valve timing.
  19. Install components in reverse order of removal.
  20. Check headlamp alignment.
  21. Tighten crankshaft pulley bolts [5] . Tightening torque: 10 Nm + 90°. Use new bolts.
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