Timing belt replacement DIY guide for 2002 A6 3.0L
#1
06-27-2007, 02:42 PM
Timing belt replacement DIY guide for 2002 A6 3.0L
Hi Guys,
I went through the whole forum but couldn't find a place where I can get DIY guide to replace Timing Belt on 2002 A6 3.0L. Can someone please point me to a place where I can get the instructions?
I can do normal DIY on my car like changing oil, coolant etc. But this would be my first time doing the Timing Belt? Want to do it to save money and for fun. Any suggestions? What are the chances of screwing it up?
I went through the whole forum but couldn't find a place where I can get DIY guide to replace Timing Belt on 2002 A6 3.0L. Can someone please point me to a place where I can get the instructions?
I can do normal DIY on my car like changing oil, coolant etc. But this would be my first time doing the Timing Belt? Want to do it to save money and for fun. Any suggestions? What are the chances of screwing it up?
#2
06-27-2007, 03:28 PM
RE: Timing belt replacement DIY guide for 2002 A6 3.0L
YOUR A BRAVE MAN more pictures to follow
Dismantling and assembling engine[/align] Removing and installing toothed belt[/align]
Special tools and workshop equipment required â—†Pin wrench 3212 â—†Pin wrench 3387 â—†Locking pin T40011 â—†Fixing screw T40026 â—†Socket T40028 â—†Retainers T40030 [/ul]
Removing â—Lock carrier must be in service position => Page 13-2. â—Ribbed belt must be removed => Page 13-12. [/ul] ‒→ Unscrew bolts -arrows- and remove ribbed belt tensioner. [/ul]
‒→ Unbolt ribbed belt pulley at vane pump -arrows-, using pin wrench 3212 as a brace. [/ul]
‒→ Unscrew 8 bolts -1-. ‒Take off vibration damper -2- and thrust washer -3-. [/ul] Note: Thrust washer -3- is only fitted together with toothed belt sprocket, Part No. 06C 105 063 A. No thrust washer is fitted on vehicles with toothed belt sprocket, Part No. 06C 105 063 B.
‒→ Unscrew bolts -1 ... 12- and remove toothed belt guards. [/ul]
‒→ Pull off rear engine cover panel -arrows-. [/ul]
‒→ Unbolt coolant expansion tank -arrow-. ‒Disconnect wiring for coolant shortage indicator switch -F66 at bottom of coolant expansion tank. ‒Tie coolant expansion tank to one side with coolant hoses -1 ... 3- connected. [/ul]
‒→ Detach ACF solenoid valve -N80 -1- from air cleaner housing. ‒Unplug electrical connector -2- from air mass meter. ‒Remove air hose -3- together with air mass meter. ‒Remove air cleaner housing -arrows-. [/ul]
‒→ Unscrew bolts -1- and -2-. ‒Disconnect hose -4- at pipe for secondary air system. ‒Pull oil dipstick guide tube -3- upwards out of sump (upper section), pivot forward and remove. [/ul]
‒→ Unscrew bolts -5- and -6- on right cylinder head cover. ‒Unplug electrical connectors -1 ... 4-. ‒Pull out ignition coils -arrows-. [/ul]
‒→ Detach crankcase breather hose -arrow-. ‒Remove bolts on right cylinder head cover in the sequence -12 ... 1-. ‒Remove cylinder head cover. [/ul]
‒→ Unscrew bolts -4- and -5- on left cylinder head cover. ‒Unplug electrical connectors -1 ... 3- and -6-. ‒Pull out ignition coils -arrows-. [/ul]
‒→ Detach crankcase breather hose -arrow-. ‒Remove bolts on left cylinder head cover in the sequence -12 ... 1-. ‒Remove cylinder head cover. [/ul]
Warning
The engine must only be turned over at the crankshaft in direction of engine rotation (clockwise).[/align] ‒→ Turn engine until cams -arrows- of intake and exhaust camshafts at cylinder No. 3 (right cylinder bank) point upwards at equal angles. [/ul] Note: Turn over the engine at the central bolt on the crankshaft.
‒→ Attach retainer T40030 to camshafts of right cylinder head. [/ul] Note: Turn crankshaft slightly backwards and forwards so that lugs of retainer T40030 can engage properly on camshafts. ‒Expand retainer T40030 by means of the threaded spindle (tightening torque not more than 10 Nm) until it is seated with zero play. [/ul]
‒→ Attach retainer T40030 on left cylinder head in the same way. [/ul]
‒If fitted, unplug electrical connector at coolant run-on pump. ‒Unscrew plug for TDC marking from cylinder block. ‒→ Screw fixing screw T40026 into hole where plug has been removed, and tighten fixing screw.[/ul] Note: If necessary, turn crankshaft slightly backwards and forwards.
Note: Catch escaping oil with a cloth. ‒→ Prise off circlips -1- for caps -2- on all camshaft sprockets. [/ul]
‒→ Slacken bolts -1 ... 4- for camshaft sprockets. [/ul] Note: Leave bolts in place but slack.
‒→ Turn toothed belt tensioning roller in direction of arrow using an 8 mm socket key until tensioning lever of belt tensioner is compressed far enough to allow mandrel T40011 to be inserted into the holes in the piston and the housing. [/ul] Notes: ◆The toothed belt tensioner is oil-damped, and can only be compressed slowly by applying continuous pressure. ◆Mark direction of rotation of toothed belt. The belt can break if it rotates in the opposite direction when refitted. [/ul]
‒→ Slacken bolt -arrow- on eccentric wheel. ‒Take off toothed belt. [/ul] Installing (adjusting valve timing) â—Camshafts locked in position with retainers T40030 â—Crankshaft locked in position with fixing screw T40026 â—Camshaft sprockets able to turn. [/ul] Notes: â—†Replace gaskets, seals and self-locking bolts. â—†Ensure that none of the pistons are at TDC when the camshaft is turned, otherwise the valves and piston crowns can be damaged. [/ul]
‒→ Tighten the camshaft sprocket bolts -1 ... 4- until the sprockets can still just be turned, but do not move axially. ‒Fit toothed belt as illustrated. ‒To ensure accurate valve timing adjustment, the toothed belt must be exactly in line with the front edge of all belt sprockets. [/ul][/ul]
‒→ Using pin wrench 3387, turn the eccentric wheel clockwise until the handle of the pin wrench is exactly over the centre axis of coolant pump pulley -2-. ‒Hold pin wrench in this position and tighten bolt -3- to 45 Nm. [/ul]
‒→ Apply torque wrench horizontally to hexagon socket of tensioner lever. ‒To pre-tension toothed belt, apply a torque of 45 Nm in the direction indicated (arrow). [/ul]
‒→ Apply pressure to toothed belt tensioning roller in direction of arrow using an 8 mm socket key until mandrel T40011 can be pulled out. [/ul]
‒→ Apply torque wrench horizontally to hexagon socket of tensioner lever. ‒To tension toothed belt, apply a torque of 25 Nm in the direction indicated (arrow). [/ul]
‒→ Apply socket T40028 to camshaft adjuster on exhaust camshaft on left cylinder bank. ‒Turn rotor of camshaft adjuster clockwise as far as it will go -arrow- with a torque of 10 Nm. [/ul]
‒→ Turn rotor of camshaft adjuster on right cylinder bank clockwise as far as it will go -arrow- with a torque of 10 Nm. ‒Tighten camshaft sprocket bolts to 100 Nm. [/ul]
‒→ Install caps -2- with new O-rings -1- on camshaft sprockets and secure with circlips. ‒Remove retainers T40030. ‒Remove fixing screw T10026 and screw plug for TDC marking into cylinder block together with new O-ring. [/ul] The remaining installation steps are carried out in the reverse sequence - note the following points: ‒Install cylinder head covers => Page 15-28. ‒Install toothed belt guards => Page 13-18. ‒Install vibration damper
=> Page 13-16. ‒Install ribbed belt =>Page 13-15. [/ul] Tightening torques
Component
Nm Eccentric wheel to front sealing flange
45 Camshaft sprocket to camshaft 100 Plug in cylinder block 25 Ribbed belt tensioner to cylinder block M8 23
M10 40 Pulley to vane pump 23
[IMG]local://upfiles/12092/4F8E7125A1DA4FF78A7C540C0EF732E8.jpg[/IMG]
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Dismantling and assembling engine[/align] Removing and installing toothed belt[/align]
Special tools and workshop equipment required â—†Pin wrench 3212 â—†Pin wrench 3387 â—†Locking pin T40011 â—†Fixing screw T40026 â—†Socket T40028 â—†Retainers T40030 [/ul]
Removing â—Lock carrier must be in service position => Page 13-2. â—Ribbed belt must be removed => Page 13-12. [/ul] ‒→ Unscrew bolts -arrows- and remove ribbed belt tensioner. [/ul]
‒→ Unbolt ribbed belt pulley at vane pump -arrows-, using pin wrench 3212 as a brace. [/ul]
‒→ Unscrew 8 bolts -1-. ‒Take off vibration damper -2- and thrust washer -3-. [/ul] Note: Thrust washer -3- is only fitted together with toothed belt sprocket, Part No. 06C 105 063 A. No thrust washer is fitted on vehicles with toothed belt sprocket, Part No. 06C 105 063 B.
‒→ Unscrew bolts -1 ... 12- and remove toothed belt guards. [/ul]
‒→ Pull off rear engine cover panel -arrows-. [/ul]
‒→ Unbolt coolant expansion tank -arrow-. ‒Disconnect wiring for coolant shortage indicator switch -F66 at bottom of coolant expansion tank. ‒Tie coolant expansion tank to one side with coolant hoses -1 ... 3- connected. [/ul]
‒→ Detach ACF solenoid valve -N80 -1- from air cleaner housing. ‒Unplug electrical connector -2- from air mass meter. ‒Remove air hose -3- together with air mass meter. ‒Remove air cleaner housing -arrows-. [/ul]
‒→ Unscrew bolts -1- and -2-. ‒Disconnect hose -4- at pipe for secondary air system. ‒Pull oil dipstick guide tube -3- upwards out of sump (upper section), pivot forward and remove. [/ul]
‒→ Unscrew bolts -5- and -6- on right cylinder head cover. ‒Unplug electrical connectors -1 ... 4-. ‒Pull out ignition coils -arrows-. [/ul]
‒→ Detach crankcase breather hose -arrow-. ‒Remove bolts on right cylinder head cover in the sequence -12 ... 1-. ‒Remove cylinder head cover. [/ul]
‒→ Unscrew bolts -4- and -5- on left cylinder head cover. ‒Unplug electrical connectors -1 ... 3- and -6-. ‒Pull out ignition coils -arrows-. [/ul]
‒→ Detach crankcase breather hose -arrow-. ‒Remove bolts on left cylinder head cover in the sequence -12 ... 1-. ‒Remove cylinder head cover. [/ul]
Warning
The engine must only be turned over at the crankshaft in direction of engine rotation (clockwise).[/align] ‒→ Turn engine until cams -arrows- of intake and exhaust camshafts at cylinder No. 3 (right cylinder bank) point upwards at equal angles. [/ul] Note: Turn over the engine at the central bolt on the crankshaft.
‒→ Attach retainer T40030 to camshafts of right cylinder head. [/ul] Note: Turn crankshaft slightly backwards and forwards so that lugs of retainer T40030 can engage properly on camshafts. ‒Expand retainer T40030 by means of the threaded spindle (tightening torque not more than 10 Nm) until it is seated with zero play. [/ul]
‒→ Attach retainer T40030 on left cylinder head in the same way. [/ul]
‒If fitted, unplug electrical connector at coolant run-on pump. ‒Unscrew plug for TDC marking from cylinder block. ‒→ Screw fixing screw T40026 into hole where plug has been removed, and tighten fixing screw.[/ul] Note: If necessary, turn crankshaft slightly backwards and forwards.
Note: Catch escaping oil with a cloth. ‒→ Prise off circlips -1- for caps -2- on all camshaft sprockets. [/ul]
‒→ Slacken bolts -1 ... 4- for camshaft sprockets. [/ul] Note: Leave bolts in place but slack.
‒→ Turn toothed belt tensioning roller in direction of arrow using an 8 mm socket key until tensioning lever of belt tensioner is compressed far enough to allow mandrel T40011 to be inserted into the holes in the piston and the housing. [/ul] Notes: ◆The toothed belt tensioner is oil-damped, and can only be compressed slowly by applying continuous pressure. ◆Mark direction of rotation of toothed belt. The belt can break if it rotates in the opposite direction when refitted. [/ul]
‒→ Slacken bolt -arrow- on eccentric wheel. ‒Take off toothed belt. [/ul] Installing (adjusting valve timing) â—Camshafts locked in position with retainers T40030 â—Crankshaft locked in position with fixing screw T40026 â—Camshaft sprockets able to turn. [/ul] Notes: â—†Replace gaskets, seals and self-locking bolts. â—†Ensure that none of the pistons are at TDC when the camshaft is turned, otherwise the valves and piston crowns can be damaged. [/ul]
‒→ Tighten the camshaft sprocket bolts -1 ... 4- until the sprockets can still just be turned, but do not move axially. ‒Fit toothed belt as illustrated. ‒To ensure accurate valve timing adjustment, the toothed belt must be exactly in line with the front edge of all belt sprockets. [/ul][/ul]
‒→ Using pin wrench 3387, turn the eccentric wheel clockwise until the handle of the pin wrench is exactly over the centre axis of coolant pump pulley -2-. ‒Hold pin wrench in this position and tighten bolt -3- to 45 Nm. [/ul]
‒→ Apply torque wrench horizontally to hexagon socket of tensioner lever. ‒To pre-tension toothed belt, apply a torque of 45 Nm in the direction indicated (arrow). [/ul]
‒→ Apply pressure to toothed belt tensioning roller in direction of arrow using an 8 mm socket key until mandrel T40011 can be pulled out. [/ul]
‒→ Apply torque wrench horizontally to hexagon socket of tensioner lever. ‒To tension toothed belt, apply a torque of 25 Nm in the direction indicated (arrow). [/ul]
‒→ Apply socket T40028 to camshaft adjuster on exhaust camshaft on left cylinder bank. ‒Turn rotor of camshaft adjuster clockwise as far as it will go -arrow- with a torque of 10 Nm. [/ul]
‒→ Turn rotor of camshaft adjuster on right cylinder bank clockwise as far as it will go -arrow- with a torque of 10 Nm. ‒Tighten camshaft sprocket bolts to 100 Nm. [/ul]
‒→ Install caps -2- with new O-rings -1- on camshaft sprockets and secure with circlips. ‒Remove retainers T40030. ‒Remove fixing screw T10026 and screw plug for TDC marking into cylinder block together with new O-ring. [/ul] The remaining installation steps are carried out in the reverse sequence - note the following points: ‒Install cylinder head covers => Page 15-28. ‒Install toothed belt guards => Page 13-18. ‒Install vibration damper
=> Page 13-16. ‒Install ribbed belt =>Page 13-15. [/ul] Tightening torques
Component
Nm Eccentric wheel to front sealing flange
45 Camshaft sprocket to camshaft 100 Plug in cylinder block 25 Ribbed belt tensioner to cylinder block M8 23
M10 40 Pulley to vane pump 23
[IMG]local://upfiles/12092/4F8E7125A1DA4FF78A7C540C0EF732E8.jpg[/IMG]
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#3
06-27-2007, 03:29 PM
RE: Timing belt replacement DIY guide for 2002 A6 3.0L
# still more to come
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#4
06-27-2007, 03:31 PM
RE: Timing belt replacement DIY guide for 2002 A6 3.0L
# and some more
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#5
06-27-2007, 03:33 PM
RE: Timing belt replacement DIY guide for 2002 A6 3.0L
# a few more
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#6
06-27-2007, 03:38 PM
RE: Timing belt replacement DIY guide for 2002 A6 3.0L
# thats it enjoy
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#8
06-27-2007, 04:22 PM
RE: Timing belt replacement DIY guide for 2002 A6 3.0L
this isnt a first time DIY job thing so not for the faint hearted and you could easly screw up but saying that I know a few who did their own and took the a week to finish it lol
ps/- not a good thing to edit a post with another question it might not be seen by others ( always post a new post if you need an answer )
ps/- not a good thing to edit a post with another question it might not be seen by others ( always post a new post if you need an answer )
#10
03-11-2008, 01:46 AM
RE: Timing belt replacement DIY guide for 2002 A6 3.0L
Haha, Techbold! your incredible, seriously m8 this makes me laugh, but is the 2.7 a lot easier to do? I really don't want to DIY because I think you need a VAG? to get everything in order.