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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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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