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

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

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.

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