How to Replace timing belt on Audi A4 (B6) 1.9 TDI 2001

Audi A4 (B6) 1.9 TDI 2001 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Camshaft locking tool – No.3359.
• Crankshaft sprocket locking tool – No.T10050.
• Support guides – No.3369.
• Tensioner locking tool – No.T10008.
• Two-pin wrench – No.3387.
• Viscous fan pulley holding tool – No.3212. 4 mm drill bit.

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	2,60
Camshaft drive belt/chain, AT – R & I	2,60

Valve timing procedures

Removal

1. Move radiator support panel into service position:
   • Remove front bumper.
   • Remove air intake pipe between front panel and air filter.
   • Remove front panel bolts [1] & [2] .
   • Install support guides No.3369 in front panel [3] .
   • Slide front panel forward.
2. Raise and support front of vehicle.
3. Disconnect exhaust pipe for auxiliary heater from engine undershield (if fitted).
4. Remove:
   • Engine top cover.
   • Engine undershield.
   • Auxiliary drive belt.
   • Cooling fan assembly. Use tool No.3212.
   • Auxiliary drive belt tensioner.
   • Bolts for coolant pipe brackets (if required).
   • Timing belt upper cover [4] .
5. Move turbocharger (TC) wastegate regulating valve.
6. Remove:
   • Crankshaft pulley bolts [5] .
   • Crankshaft pulley [6] .
   • Timing belt centre cover [7] .
   • Timing belt lower cover [8] .
7. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing mark aligned with notch on camshaft sprocket hub [9] .
   NOTE: Notch located behind camshaft sprocket teeth.
8. Lock crankshaft sprocket [10] . Use tool No.T10050.
9. Ensure timing marks aligned [11] .
10. Lock camshaft [12] . Use tool No.3359.
11. Fully insert Allen key into tensioner pulley [13] .
12. Turn tensioner pulley slowly anti-clockwise until locking tool can be inserted [14] . Tool No.T10008.
13. Slacken tensioner nut [15] .
14. Remove:
    • Automatic tensioner unit [16] .
    • Timing belt.

Installation

1. Ensure camshaft locked with tool [12] . Tool No.3359.
2. Ensure crankshaft sprocket locking tool located correctly [10] . Tool No.T10050.
3. Ensure timing marks aligned [11] .
4. Ensure automatic tensioner unit locked with tool [14] . Tool No.T10008.
5. Slacken camshaft sprocket bolts [17] .
6. Turn camshaft sprocket fully clockwise in slotted holes. Tighten bolts finger tight [17] .
7. Turn tensioner pulley slowly clockwise [18] until lug [19] just reaches stop [20] . Use tool No.3387 [21] .
8. Fit timing belt in following order:
   • Camshaft sprocket.
   • Tensioner pulley.
   • Crankshaft sprocket.
   • Water pump sprocket.
9. Install automatic tensioner unit [16] .
10. Turn tensioner pulley slowly anti-clockwise [22] (lug [19] moves towards stop [23] ). Use tool No.3387 [21] .
11. Remove locking tool without force [14] .
    NOTE: Ensure two-pin wrench remains in position.
12. Allow tensioner pulley to turn back slowly [21] (lug [19] moves towards stop [20] ) until dimension [24] is 4±1 mm. Use drill bit.
    NOTE: Engine must be COLD.
13. Tighten tensioner nut [15] . Tightening torque: 20 Nm + 45°.
14. Tighten camshaft sprocket bolts [17] . Tightening torque: 25 Nm.
15. Remove:
    • Camshaft locking tool [12] .
    • Crankshaft sprocket locking tool [10] .
    • Drill bit.
16. Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
17. Ensure dimension [24] is 4±1 mm. Use drill bit.
18. If not: Slacken tensioner nut [15] . Turn tensioner pulley until dimension as specified [24] . Tighten tensioner nut [15] . Tightening torque: 20 Nm + 45°.
19. Lock crankshaft sprocket [10] . Use tool No.T10050.
20. Ensure timing marks aligned [11] .
21. Ensure camshaft locking tool can be inserted easily [12] . Tool No.3359.
22. If not:
    • Slacken camshaft sprocket bolts [17] .
    • Turn sprocket hub until locking tool can be inserted [12] .
    • Tighten bolts [17] . Tightening torque: 25 Nm.
    • Remove locking tools [10] & [12] .
    • Turn crankshaft slowly two turns clockwise to TDC on No.1 cylinder.
    • Ensure locking tools can be fitted correctly [10] & [12] .
23. Remove:
    • Camshaft locking tool [12] .
    • Crankshaft locking tool [10] .
    • Drill bit.
24. Install components in reverse order of removal.
25. Tighten crankshaft pulley bolts [5] . Tightening torque: 10 Nm + 90°. Use new bolts.