Removal & Installation Audi A8 D3

1. Raise and support vehicle. Remove noise insulation panel from under front of vehicle.
2. Remove trim cover at front of engine compartment. Remove air intake duct for air cleaner. Remove engine top trim cover and cylinder head trim covers.
3. Remove outer ring for viscous fan. Hold viscous cooling fan pulley with pin wrench (3212). (Scheme 1) Remove viscous fan by turning clockwise. Viscous fan is LEFT-HAND threaded.
4. Using box wrench, turn serpentine belt tensioner clockwise with 19 mm ring wrench until the two holes are aligned. Hold tensioner in position with pin (3204). (Scheme 2) Remove serpentine belt.
5. Disengage spring clips at timing belt covers. Remove timing belt covers.
6. Rotate crankshaft by hand to TDC of compression stroke. Ensure TDC mark on vibration dampener aligns with mark on engine. (Scheme 3)
7. Check position of camshafts. Larger hole in camshaft sprocket securing plates must face inboard and align with each other. (Scheme 4)
8. Remove sealing plug from lower left side of engine block. TDC drilling in crankshaft MUST be behind sealing plug hole. Screw Crankshaft Clamping Bolt (3242) into hole. (Scheme 5)
9. Remove serpentine belt tensioner from front of engine block. Remove vibration dampener retaining bolts. It is NOT necessary to remove center bolt. Remove vibration dampener.
10. Remove bracket for viscous cooling fan. (Scheme 6)
11. Using 8-mm hex wrench, SLOWLY compress hydraulic timing belt tensioner by turning tensioning lever counterclockwise. (Scheme 7) Insert Spring Pin (T40011) through top of timing belt tensioner and through hole in top of tensioner piston.
12. Install Camshaft Bar (T40005) onto securing plates of both camshafts. (Scheme 8)
13. Loosen both camshaft sprocket securing bolts about 5 turns. Remove Camshaft Bar (T40005). Using 2-jaw gear puller, loosen camshaft sprockets so that they are free to rotate, but not tilt, on the end of the camshaft.
14. Loosen center bolt of timing belt tensioner pulley with eccentric center. Tensioner pulley is located above and to the right of crankshaft sprocket. Remove timing belt along with camshaft sprocket for cylinders No. 1 through No. 4 (passenger side cylinder head).

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Installation

1. Ensure crankshaft is still at TDC position. Place timing belt over crankshaft sprocket, tensioner pulleys, camshaft sprocket for cylinders No. 5 through No. 8, water pump pulley and dampener pulley. Then take camshaft sprocket for cylinder bank 1-4, install toothed belt and bolt sprocket onto camshaft.
2. Lightly secure both camshaft sprockets with securing plates by tightening hand-tight. Camshaft sprockets must be tight enough on camshaft tapers to be turned, but should not tilt back and forth.
3. Attach Camshaft Bar (T40005) to camshafts. Insert a 5-mm drill bit between the tensioning lever and the tip of the hydraulic tensioner piston.
4. Set initial timing belt tension using Tensioning Key (T40009), Socket Attachment (5122) and Torque Wrench (1410). (Scheme 9) Set tension to 35 INCH lbs. (4 N.m). While holding tensioner at this point, tighten center nut to 16 ft. lbs. (22 N.m). Remove 5-mm drill bit.
5. Using 8-mm hex wrench, rotate timing belt tensioning lever counterclockwise until Spring Pin (T40011) can be removed from hydraulic tensioner.
6. Rotate timing belt tensioner lever CLOCKWISE until a 7-mm drill bit can be inserted between the tip of the tensioning lever and the top of the hydraulic tensioner body. Tighten camshaft sprocket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155549-S22795355522003061700000). Keep Camshaft Bar (T40005) in place to prevent camshafts from moving.
7. Remove Camshaft Bar (T40005) after camshaft sprocket bolts are tightened. Remove 7-mm drill bit. Remove Crankshaft Clamping Bolt (3242) from side of engine block. Install sealing plug in hole. Turn crankshaft 2 revolutions in normal direction of rotation.
8. Measure distance between tensioning lever and top of hydraulic tensioner body. Dimension should be.197" (5 mm). (Scheme 10) If dimension is not correct, readjust timing belt tension until dimension is.197" (5 mm).
9. Measure clearance between bottom of right hand timing belt guard and top of timing belt. (Scheme 11) If clearance is not correct, turn crankshaft until all rear timing belt cover bolts are exposed. Loosen bolts and adjust clearance to.0393" (1 mm). Tighten rear timing belt cover bolts.
10. Measure clearance between bottom of left hand timing belt guard and top of timing belt. (Scheme 12) If clearance is not correct, turn crankshaft by hand until all rear timing belt cover bolts are exposed. Loosen bolts and adjust clearance to.0393" (1 mm). Tighten rear timing belt cover bolts.
11. Install vibration dampener. Align notch in vibration dampener with locating lug on timing belt sprocket. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155549-S22795355522003061700000). To complete installation, reverse removal procedure. When installing serpentine belt, rotate tensioner clockwise and remove pin.

Scheme 9

Scheme 10

Scheme 11

Scheme 12