Timing Belt Replacement - 1.8l (amb) Audi A4 B6

MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE

The manufacturer suggests the belt be replaced at 105,000 mile intervals under normal driving conditions, 52,500 mile intervals under severe driving conditions.

REMOVAL & INSTALLATION

Note. Many service operations are made easier by moving lock carrier into service position.

Removal (Avant & Sedan)

1. Raise and support vehicle. Remove front tires. Remove bolts and quick release screws (1 and 2). (Scheme 43) Rear noise insulation (3) remains installed.
2. For vehicles with auxiliary heater, remove bolts for exhaust pipe of parking/auxiliary heater at noise insulation. (Scheme 44)
3. Remove right cover in engine compartment. Unbolt air guide between lock carrier and air filter on lock carrier. Remove left cover in engine compartment. Pull off hood seal from lock carrier and fender edges.
4. Loosen left and right wheelhousing liners in front area. (Scheme 45) Pull back wheelhousing liner (A). Remove bolt (2) and nuts (1). Unclip bumper rear edge from catch (B). (Scheme 46) Repeat procedure on opposite side of the vehicle.
5. Release catches (1-4) using a screwdriver and remove air inlet grille on left and right on bottom part of bumper. (Scheme 47) Remove left and right retaining bolts until bumper is fully released. (Scheme 48)
6. If installed, disconnect hose (1) to headlight cleaning system. Disconnect harness connectors (2) and remove bumper. (Scheme 49)
7. Inspect headlight and turn signal electrical connectors and wiring harness (which may hang up when lock carrier is moved forward).
8. On right side, remove bolt (5) and install support tool (3369) in its place. (Scheme 50)and see scheme 9.
9. On left side, install support tool (3369) in threaded hole in chassis. see scheme 10
10. Remove on both sides, all bolts (2). (Scheme 50)
11. Remove on both sides, all bolts (3 and 4). (Scheme 50) Slide lock carrier forward unit the rear bolt hole in lock carrier aligns with the forward threaded fender bolt hole.
12. Secure lock carrier in this position, by placing fender bolts in holes. see scheme 11 To install, reverse placing in service position procedure.
13. Remove engine cover by lifting up. Swivel tensioning element in direction of arrow to slacken off ribbed belt. see scheme 12 Lock tensioner using a mandrel (T10060) and remove ribbed belt. see scheme 13 Remove ribbed belt tensioner.
14. Remove upper part of timing belt cover. Bring engine to TDC cylinder 1. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1. see scheme 14 Remove vibration damper. Remove center and lower part of timing belt cover.
15. When compressing the tensioner, excessive force can damage the tensioning pulley. Push pulley counterclockwise in direction of arrow with a socket head wrench using even (but not excessive) application of force until tensioner piston can be locked with Locking Plate (T10008). see scheme 15
16. To release tension from timing belt, loosen nut on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool (3387). see scheme 16 Remove timing belt.

Removal (Cabriolet)

1. Loosen bolts or quick release fasteners (1 and 2). see scheme 17 The rear noise insulation quick-release fasteners (3) remain installed. The quick-release fasteners remain in the bumper cover (1).
2. Loosen the wheel housing liners on left and right at front. Pull the wheel housing liner back. Remove the bolt (2) and nuts (1). see scheme 18 Unclip bumper extension from catch (B).
3. Remove bolts and tilt front grille slightly forward and pull it out in an upward direction from bumper cover. Remove bolts (1-8) and pull side extensions out of guide piece. see scheme 19 Pull bumper cover forward slightly.
4. If equipped, disconnect hose for headlight washer unit. Disconnect connector(s) and remove bumper cover from vehicle.
5. Remove left and right engine compartment covers. Remove air duct between lock carrier and air cleaner (air duct is bolted to lock carrier). Install Lock Carrier Support Tool (3369) into thread on left and right side near impact absorbers. see scheme 9and see scheme 20.
6. Remove bolts (4 and 5) and pull lock carrier forward. Pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender flange. see scheme 11
7. Remove engine cover by lifting up. Swivel tensioning element in direction of arrow to slacken off ribbed belt. see scheme 12 Lock tensioner using a mandrel (T10060) and remove ribbed belt. see scheme 13 Remove ribbed belt tensioner.
8. Remove upper part of timing belt cover. Bring engine to TDC cylinder 1. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1. see scheme 14 Remove vibration damper. Remove center and lower part of timing belt cover.
9. When compressing the tensioner, excessive force can damage the tensioning pulley. Push pulley counterclockwise in direction of arrow with a socket head wrench using even (but not excessive) application of force until tensioner piston can be locked with Locking Plate (T10008). see scheme 15
10. To release tension from timing belt, loosen nut on pulley and rotate eccentric bolt clockwise in direction of arrow using special tool (3387). see scheme 16 Remove timing belt.

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Installation (Avant & Sedan)

1. Place timing belt on crankshaft sprocket (if reusing belt, observe direction of rotation). Install lower part of timing belt cover. Install vibration dampener. The hole in the vibration damper must be located over the raised part on the crankshaft timing belt sprocket. Tighten vibration damper/pulley to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications).
2. If necessary, align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-timing belt cover positioning marks. see scheme 14 Install timing belt in this order: water pump, tensioning pulley, camshaft sprocket. NOTE: If the timing belt tensioner has not been restrained and is at its travel limit, it must be pushed back in the installed position together with the pulley. This procedure can take up to 5 minutes. When compressing the tensioner, excessive force can damage the tensioning pulley. Push pulley on counterclockwise in direction of arrow with a socket head wrench using even (but not excessive) application of force until tensioner piston can be locked with Locking Plate (T10008). see scheme 15
3. Turn eccentric bolt counterclockwise in direction of arrow using special tool (3387). see scheme 21 Hold eccentric bolt in this position and remove locking plate. Turn eccentric bolt clockwise to right in direction of arrow until a gauge with dimension of 8 mm (e.g., drill bit) can be passed between tensioning lever and tensioner housing. see scheme 22 Hold eccentric bolt in this position and tighten pulley nut to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications).
4. Turn crankshaft two complete turns by hand in direction of engine rotation until crankshaft is at TDC again. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1. see scheme 14 Check dimension between tensioning lever and tensioner housing with a gauge. Dimension should be 6-10 mm. If dimension is not obtained, tension timing belt again. Go to step 3.
5. Install center and upper timing belt cover and ribbed belt tensioner. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications). When installing ribbed belt, make sure that direction of rotation is correct and that belt is installed correctly to pulleys. On vehicles with A/C, install ribbed belt to A/C compressor last.
6. To install lock carrier, reverse removal procedures outlined in «REMOVAL (AVANT & SEDAN)»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__removal-avant-sedan). Torque all fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications). Let support stop rest on rubber buffer for torque support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). see scheme 23
7. Slide bumper onto impact absorber and re-connect hose (1) of headlight cleaning system and electrical harness connectors (2). (Scheme 49) Move bumper into installation position. Make sure threaded pins in bumper side edges engage into holes at the fenders. Install bumper retaining bolts until bumper can stay in place without any assistance.
8. Do not tighten completely allowing for any necessary adjustments. Pull back wheelhousing liner (A). (Scheme 45) Engage bumper rear edge into catch (B). Torque nuts. Repeat procedure on opposite side of the vehicle. Torque left and right retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications). Install left and right air inlet grille on bumper. Remainder of installation is the reverse of removal.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Place timing belt on crankshaft sprocket (if reusing belt, observe direction of rotation). Install lower part of timing belt cover. Install vibration dampener. The hole in the vibration damper must be located over the raised part on the crankshaft timing belt sprocket. Tighten vibration damper/pulley to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications).
2. If necessary, align camshaft sprocket-to-cylinder head cover positioning marks and vibration damper-to-timing belt cover positioning marks. see scheme 14 Install timing belt in this order: water pump, tensioning pulley, camshaft sprocket. NOTE: If the timing belt tensioner has not been restrained and is at its travel limit, it must be pushed back in the installed position together with the pulley. This procedure can take up to 5 minutes. When compressing the tensioner, excessive force can damage the tensioning pulley. Push pulley on counterclockwise in direction of arrow with a socket head wrench using even (but not excessive) application of force until tensioner piston can be locked with Locking Plate (T10008). see scheme 15
3. Turn eccentric bolt counterclockwise in direction of arrow using special tool (3387). see scheme 21 Hold eccentric bolt in this position and remove locking plate. Turn eccentric bolt clockwise to right in direction of arrow until a gauge with dimension of 8 mm (e.g., drill bit) can be passed between tensioning lever and tensioner housing. see scheme 22 Hold eccentric bolt in this position and tighten pulley nut to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications).
4. Turn crankshaft two complete turns by hand in direction of engine rotation until crankshaft is at TDC again. Mark on camshaft sprocket and mark on crankshaft must be at TDC cylinder 1. see scheme 14 Check dimension between tensioning lever and tensioner housing with a gauge. Dimension should be 6-10 mm. If dimension is not obtained, tension timing belt again. Go to step 3.
5. Install center and upper timing belt cover and ribbed belt tensioner. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications). When installing ribbed belt, make sure that direction of rotation is correct and that belt is installed correctly to pulleys. On vehicles with A/C, install ribbed belt to A/C compressor last.
6. To install lock carrier, reverse removal procedures outlined in «REMOVAL (CABRIOLET)»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__removal-cabriolet). Torque all fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications).
7. To install bumper cover, reverse removal procedures outlined in «REMOVAL (CABRIOLET)»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__removal-cabriolet). Slide bumper cover onto lock carrier and connect the hose of headlight washer unit as necessary. Reconnect connectors as necessary. Ensure that the threaded pins in the bumper side extensions engage in the holes at the fender.
8. Clip in side extensions and fasten using the bolts (8). see scheme 19 Loosely screw in bolt (3). Tighten bolts (2 and 4) to 48 INCH lbs. (6 N.m), and bolts (5, 6 and 7) to 24 INCH lbs. (3 N.m). Close hood and check overlap or gap dimension of bumper cover with respect to the hood. If OK, tighten all the bolts. If not, open hood and loosen bolts (2 or/and 4) to correct upper bumper as required. Tighten bolt (3) to 48 INCH lbs. (6 N.m).
9. Verify fender gaps are as follow: A = 2 mm +/- 0.5 mm, B = 0 mm +/- 0.5 mm and C = 0 mm +/- 0.5 mm. see scheme 24 Gap dimensions can be checked using Audi special tool (3371). Adjust gaps as necessary. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/audi/a4/b6-2000-2006/remont/timing-belt/#timing-belt-replacement-18l-amb__torque-specifications). Remainder of installation is the reverse of removal.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• REMOVAL (AVANT & SEDAN)
• REMOVAL (CABRIOLET)