Removal & Installation Audi A6 C5

Note. Obtain radio anti-theft code before disconnecting battery.

1. Disconnect negative battery cable. Remove engine top cover. Working under vehicle, remove noise insulation panel from under front of vehicle.
2. Remove front bumper. (Scheme 1)or (Scheme 2). Remove air intake duct from air cleaner housing. On right side of lock carrier, remove bolt and install Lock Carrier Support Tool (3369). (Scheme 3), (Scheme 4) and (Scheme 5). Remove lock carrier-to-body bolts. Carefully slide lock carrier forward on support tool.
3. Hold cooling fan pulley with spanner wrench. Unscrew and remove viscous cooling fan clutch from pulley. Viscous cooling fan is LEFT-HAND threaded.
4. Use a 17-mm box wrench to turn serpentine belt tensioner counterclockwise to relieve belt tension and remove serpentine belt. If reusing belt, mark belt rotation direction with arrow for reassembly reference.
5. Unclip left and right timing belt guards and remove. Turn crankshaft in normal direction of rotation until TDC marks on crankshaft pulley and timing belt cover are aligned. (Scheme 6)and (Scheme 7).
6. Note securing plate on front end of each camshaft sprocket. Large holes of securing plates on camshaft sprockets must face toward inside and align. If large hole in each plate does not face inward, toward center of engine, rotate crankshaft one revolution. (Scheme 8) Ensure crankshaft timing marks are still aligned.
7. Remove sealing plug from left side of engine block. TDC mark on crankshaft must be visible or be felt through sealing plug hole. Install Crankshaft Holding Tool (Audi 3242) into sealing plug hole. (Scheme 9)
8. Using an 8-mm hex wrench, SLOWLY turn timing belt tensioner pulley clockwise to compress timing belt tensioner. (Scheme 10) Compress timing belt tensioner just enough so that a 2-mm pin can be inserted through the holes in top of tensioner body and push rod. This will hold the tensioner in the compressed position.
9. Remove crankshaft vibration damper from crankshaft. It is NOT necessary to remove center bolt. If center bolt is removed, manufacturer recommends using NEW bolt on reassembly. Remove serpentine belt idler pulley.
10. Remove lower timing belt guard (if equipped). Remove timing belt.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Installation

1. Install Camshaft Locator Bar (3391) into locking plates of camshafts. (Scheme 12) Loosen camshaft sprocket bolts about 5 turns. Remove locator bar. Leaving camshaft sprocket bolts in place, use gear puller to loosen camshaft sprockets on camshaft taper.
2. Ensure all timing marks are still aligned. Install timing belt on engine. Ensure belt routing is correct and there is no slack in belt. (Scheme 13) Install Camshaft Locator Bar (3391) into locking plates of camshafts.
3. Using an 8-mm hex wrench, SLOWLY compress timing belt tensioner so that 2-mm pin can be removed from tensioner.
4. Using 8-mm hex socket, place torque wrench on timing belt tensioner pulley. Apply 11 ft. lbs. (15 N.m) to tensioner in direction of tension (clockwise). This will preload belt tension.
5. Tighten camshaft sprocket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155386-S17648973652003061300000). Remove camshaft locator bar. Remove crankshaft holder. Install sealing plug. To complete installation, reverse removal procedure. When installing crankshaft pulley, ensure notches in pulley are aligned with locating lugs in crankshaft. On A4, A6 and Quattro models, ensure lock carrier-to-body Torx bolts are correctly positioned. (Scheme 14)

Scheme 12

Scheme 13

Scheme 14