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

A4 Audi

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 & I2,60
Camshaft drive belt/chain, AT – R & I2,60

Valve timing procedures

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

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.
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