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

A6 Audi

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:
A42,60
AT+0,30
A63,50

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

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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Bent Valves
Timing Tools?
Misconception
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Bent Valves

What happens when your chain or belt breaks. 

The timing of course becomes way off. Your crankshaft will always spin making the pistons move up and down. However the valves will remain in the position they were in when the belt or chain stopped working. 

Half of the valves will be stuck open and in the way of the pistons. Not all engines, but most. The piston out of valve time will smash right into the open valve and bend the, The only way to fix that is to remove the head and place those valves. 

If you think your valves might have been damaged.

Remove all the spark plugs, valve covers. With both valves in the closed position insert a compression tester hose in place of the spark plug and inject air into the hose and see if the cylinder can hold air. If both valve are closed and air can not be held, chances are you have bent valves.   

 

Timing Tools?

Do you need special tools to time your engine? Not always, on all my post I'll indicate that in each post if you do or not. 

But what are these special tools? Normally you would just line up some marks on the cam and crank gears and simply be done with it. However when these tools are needed they are very very important. 

The last one I did was a 2013 Range Rover 2.0 Turbo with dual cams. There were not timing marks at all. 

There is a small threaded plug on the back of the engine that I removed to insert a special threaded pin that would rest up against the weight of the crankshaft to prevent for DTC of the #1 piston. No further clockwise rotation would be possible. At that point I installed the supplied crankshaft lock by removing the starter. 

Then you line up the back of both camshafts to a notch in each camshafts to each other that a flat tool connects to each cam so they are in line with each other. But first you would make sure both intake and exhaust valves are closed DTC of the cams. 

And the last tool was to lineup the crankshaft position sensor. 

 

Misconception

The most important thing in any major engine work is to rotate the engine by hand at least two complete rotations. And do it easy and slow and with the spark plugs removed. 

Why remove the spark plugs? you may ask. Simple, with the plugs in place you'll be creating compression, making the engine harder to turn by hand and perhaps giving you the misconception of valves hitting the pistons or is it compression.  

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