How to Replace timing belt on Audi A6 quattro 3.0D TDi 2005

Audi

Audi A6 quattro 3.0D TDi 2005 cambelt change instructions and replacement interval. Full guide!

 

Special tools

  • Camshaft sprocket holding tool – No.3036.
  • Camshaft sprocket puller – No.3032.
  • Crankshaft turning tool – No.T40058.

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 & I15,00
Camshaft drive belt/chain, AT – R & I13,10
Camshaft drive belt/chain (rear) – R & I13,10
Injection pump drive belt/chain – R & I1,60

Valve timing procedures

How to Replace timing belt on Audi A6 quattro 3.0D TDi 2005

Removal

NOTE: The high-pressure fuel pump fitted to this engine does not require timing.

  1. Raise and support front of vehicle.
  2. Remove:
    • Engine top cover.
    • Air intake pipes to inlet manifolds.
    • High-pressure fuel pump belt cover [1] .
  3. Slacken tensioner pulley bolt two turns [2] .
  4. Move tensioner pulley away from belt.
  5. Hold camshaft sprocket [3] . Use tool No.3036.
  6. Slacken camshaft sprocket bolt two turns [4] .
  7. Loosen camshaft sprocket from taper [3] . Use tool No.3032.
  8. Remove:
    • Camshaft sprocket puller.
    • Camshaft sprocket bolt [4] .
    • Camshaft sprocket together with high-pressure fuel pump belt [3] .

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: If reusing old belt, observe direction of rotation marks on belt.

    1. Ensure tensioner pulley hexagon at 6 o’clock position [5] .
    2. Ensure tensioner pulley retaining lug is properly engaged [6] .
    3. Lightly tighten tensioner pulley bolt [2] .
    4. Fit belt to high-pressure fuel pump sprocket [7] .
    5. Fit camshaft sprocket together with high-pressure fuel pump belt [3] .
    6. Fit camshaft sprocket bolt [4] .
    7. Ensure belt is taut on non-tensioned side.
    8. Tighten camshaft sprocket bolt finger tight [4] .
    9. Slacken tensioner pulley bolt [2] .
    10. Turn tensioner pulley anti-clockwise until hexagon at 1 o’clock position, then clockwise until hexagon at 3 o’clock position. Use Allen key [8] .
      NOTE: DO NOT allow hexagon to move up to or beyond 12 o’clock position.
    11. Turn tensioner pulley anti-clockwise until pointer aligned with notch [9] & [10] . Use Allen key [8] .
    12. Hold tensioner pulley in position. Use Allen key [8] .
    13. Tighten tensioner pulley bolt [2] . Tightening torque: 23 Nm.
    14. Hold camshaft sprocket [3] . Use tool No.3036.
    15. Tighten camshaft sprocket bolt [4] . Tightening torque: 75 Nm.
    16. Turn crankshaft one turn clockwise. Use tool No.T40058.
    17. Ensure tensioner pulley pointer and notch aligned [9] & [10] . If not: Repeat tensioning procedure.
    18. Fit high-pressure fuel pump belt cover [1] .
    19. Install components in reverse order of removal.
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