Removal & Installation Audi S6 C5

Note. Lock carrier is slid forward onto alignment tools to allow servicing of front engine components. Lock carrier can be removed at technician's discretion.

Note. It is not necessary to completely remove noise insulation from beneath the engine. Only remove the quick-release fasteners that attach to the front bumper assembly.

1. Raise and support vehicle. Remove front tires. Remove lower front engine shield (noise insulator). (Scheme 1) Loosen the front half of the wheelhousing splash shield (liner). (Scheme 2) Remove flange nut on both sides. (Scheme 3)and (Scheme 4).
2. For vehicles with auxiliary heater, remove bolts for exhaust pipe of parking/auxiliary heater at noise insulation. (Scheme 5)
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. Release catches (1-4) using a screwdriver, and remove air inlet grille on left and right sides of bottom part of bumper. (Scheme 6) Remove left and right retaining bolts until bumper is fully released. (Scheme 7)
5. Remove screw with washer assembly (6) from wheelhousing liner (5). (Scheme 3) Disconnect any wiring harness that attaches to the front bumper. Remove socket-head bolts (7), and remove bumper cover together with impact absorber towards front. (Scheme 3)
6. Inspect headlight and turn signal electrical connectors and wiring harness (which may hang up when lock carrier is moved forward).
7. On passenger's side, remove bolt (5) and install Support Tool (3369) in its place. (Scheme 8)and (Scheme 9).
8. On driver's side, install Support Tool (3369) in threaded hole in chassis. (Scheme 10)
9. Remove bolts (2, 3 and 4) from both sides. (Scheme 8) Slide lock carrier forward unit the rear bolt hole in lock carrier aligns with the forward-threaded fender bolt hole.
10. Secure lock carrier in this position by placing fender bolts in holes. (Scheme 11)
11. Remove air intake hose to air cleaner. Remove engine cover. Using Spanner Wrench (3212) to hold fan clutch pulley, use Open-End Spanner (3312) or equivalent to loosen fan clutch. Remove radiator fan and fan shroud from vehicle.
12. Using a 19-mm wrench, rotate drive belt tensioner clockwise to loosen belt tensioner. Secure belt tensioner using Drift (3204). Remove drive belt. Ensure belt has no splits, cracks or other damage. Replace drive belt if necessary. (Scheme 12)
13. Remove upper cylinder head covers. Disengage clips and remove timing belt cover. Remove noise insulation panel. Rotate crankshaft by to Top Dead Center (TDC). (Scheme 13)
14. Check position of camshafts. Larger holes of camshaft securing plates (located on front of camshaft sprockets) must be on inside and must align. (Scheme 14) If camshafts are in correct position, go to next step. If camshafts are not in correct position, rotate crankshaft one turn further.
15. Remove sealing plug from alignment access hole in left side of engine block. Ensure that hole in crankshaft is visible through alignment access hole. Install Crankshaft Holder (3242) into alignment access hole to prevent crankshaft from rotating. (Scheme 15)
16. Remove accessory drive belt tensioner. Loosen 8 Allen-headed bolts and remove crankshaft vibration damper (center bolt does not have to be removed). Remove engine torque support. (Scheme 16)
17. Using an 8-mm wrench, turn timing belt tensioning roller counterclockwise until tensioning lever compresses tensioner so a pin (2 mm in diameter) can be inserted into plunger. (Scheme 17) Insert pin and release tension.
18. Install Camshaft Locator Bar (T40005) into camshaft locking plates. Loosen camshaft bolts and back bolts out 5 turns. Remove camshaft locator bar. Using Camshaft Sprocket Puller (T40001), remove camshaft sprocket. (Scheme 18) Loosen timing belt tensioning roller. Remove timing belt and left camshaft sprocket together.

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Scheme 18

Installation

1. Install timing belt first to crankshaft, then to tensioner, water pump, timing belt tensioning roller and right camshaft sprocket. (Scheme 19) Install left camshaft sprocket to camshaft with timing belt, and hand tighten camshaft sprocket bolts. Camshaft sprockets must be able to move on tapered camshaft.
2. Install Camshaft Holding Bar. (Scheme 20) Insert a 5-mm drill bit between timing belt tensioner and tensioner piston. (Scheme 21) Using Spanner (T40009) and torque wrench, apply 35 INCH lbs. (4 N.m) to timing belt tensioning roller. (Scheme 22) Remove drill bit.
3. Using an 8-mm Allen wrench, turn timing belt tensioner clockwise until tensioning lever compresses and remove pin. (Scheme 17) Continue turning timing belt tensioner clockwise until a 7-mm drill bit can be inserted between timing belt tensioner and tensioner piston. Tighten camshaft sprockets to 41 ft. lbs. (55 N.m).
4. Remove Camshaft Holding Bar. Remove drill bit. Turn crankshaft by hand 2 full revolutions. Measure distance between timing belt tensioner and tensioner body. (Scheme 23) Dimension should be 5 mm. If dimension is as specified, go to next step. If dimension is not as specified, repeat belt tensioning procedure.
5. Using feeler gauge, check distance between timing belt and timing belt guard at right camshaft. (Scheme 24) Dimension should be.040" (1 mm). If dimension is not as specified, go to next step. If dimension is as specified, repeat procedure on left camshaft timing belt guard.
6. Rotate crankshaft until all bolts are exposed. Loosen bolts, and move guard until dimension is.040" (1 mm). Tighten bolts to 89 INCH lbs. (10 N.m). To complete timing belt installation, reverse remaining removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-157970-S39912564802003090400000).
7. To install lock carrier, reverse removal procedures outlined in «REMOVAL»(ref-157970-S09820953602003090400000). Torque all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-157970-S39912564802003090400000). Let support stop rest on rubber buffer for torque support with its own weight and tighten bolts to 21 ft. lbs. (28 N.m). (Scheme 25)
8. Before installing the bumper, ensure the expanding clips are pressed into the fender. (Scheme 26) When installing the tabs, the bumper cover must latch into clip (4). (Scheme 3)and (Scheme 4).
9. Latch bumper cover (1) into guide (2). (Scheme 3) Torque flange nuts (10) to 53 INCH lbs. (6 N.m).
10. Torque left and right retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-157970-S39912564802003090400000). Install left and right air inlet grille on bumper. To complete installation, reverse removal procedures.

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