Audi > A4, S4 (B6, B7) > 2002 -2008 3.0 Liter 6-Cyl. 5V

Audi > A4, S4 (B6, B7) > 2002-2008 3.0 Liter 6-Cyl. 5V Engine Mechanical, Engine Code(s): AVK, BGN 13 - Removal and Installation

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Toothed Belt

Special tools, testers and auxiliary items required

Spanner Wrench 3212

Pin Wrench 3387

Locking Pin T40011

Locking Pin T40026

Socket T40028

Camshaft Adjuster Gauge T40030

Ignition Coil Puller T40039

Removing

Bring the lock carrier into service position. Refer to Lock Carrier, Moving into Service Position .

Remove ribbed belt tensioner. Refer to Ribbed Belt Tensioner .

Remove power steering pump belt pulley - arrows - using Pin Wrench 3387 to

Page 1 of 13Toothed Belt

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counterhold.

Remove 8 bolts - 1 - .

Remove vibration damper - 2 - and, if equipped, thrust washer - 3 - .

Note:

Thrust washer - 3 - is only equipped with toothed belt gear 06C 105 063 A . Thrust washer must not be installed with toothed belt gear 06C 105 063 B .

Remove bolts - 1 to 12 - and remove left front, right front and lower toothed belt guards.



Pull rear engine cover off - arrows - .

Remove coolant expansion tank - arrow - .

Disconnect electrical connection from Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant reservoir and set aside coolant reservoir with coolant hoses - 1 to 3 - connected.

Remove air filter housing - arrows - .

Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70 .



Disconnect air duct hose - 2 - together with Mass Air Flow (MAF) Sensor G70 .

Remove the bolts - 1 - and - 3 - .

Disconnect hose - 4 - to Secondary Air Injection (AIR) system pipe.

Remove oil dipstick guide tube - 2 - upward out of upper part of oil pan and swivel forward.

Remove screws - 5 - and - 6 - on right cylinder head cover.

Disconnect electrical harness connectors - 1 to 4 - .

Remove ignition coils - arrows - using Ignition Coil Puller T40039 .



Disconnect crankshaft housing ventilation hose - arrow - .

Remove bolts for right cylinder head cover in the sequence - 12 to 1 - .

Remove cylinder head cover.

Remove bolts - 4 - and - 5 - on left cylinder head cover.

Disconnect electrical harness connectors - 1 to 3 - and - 6 - .

Remove ignition coils - arrows - using Ignition Coil Puller T40039 .



Disconnect crankshaft housing ventilation hose - arrow - .

Remove bolts for left cylinder head cover in the sequence - 12 - 1 - .

Remove cylinder head cover.

Turn engine until cam lobes - arrows - to cylinder 3 (right cylinder bank) intake and exhaust camshafts face upward evenly.

Note:

Turning over the engine is performed at the central bolt of the crankshaft.

Insert Camshaft Adjuster Gauge T40030 into right cylinder head camshafts.

Note:

CAUTION!

Only turn over the engine at the crankshaft in direction of engine rotation (clockwise).



Turn crankshaft back and forth slightly so that Camshaft Adjuster Gauge T40030 claws can engage on camshafts correctly.

Spread Camshaft Adjuster Gauge T40030 with threaded rods (specified torque max. 10 Nm) until it is seated with no play.

Insert Camshaft Adjuster Gauge T40030 in the same way in left cylinder head.

If equipped, disconnect electrical connector to After-Run Coolant Pump V51 .

Remove TDC mark sealing plugs from cylinder blocks.

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Install Locking Pin T40026 into hole, if necessary rotate crankshaft very slightly back and forth to completely center the pin.



Note:

Catch escaping oil with a cloth.

Pry circlips - 1 - for cover caps - 2 - using a screwdriver - 3 - at all camshaft gears.

Loosen but do not remove bolts - 1 to 4 - .

Note:

The bolts remain loose but screwed in.



Turn toothed belt tensioning roller using 8 mm hex socket in direction of - arrow - until tensioning element on tensioning lever is pushed together enough that Locking Pin T40011 can be inserted in piston and housing holes.

Note:

The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure.

Before removing toothed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the used toothed belt.

Remove eccentric roller screw - arrow - .

Remove toothed belt.

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Installing (Adjusting valve timing)

Camshafts locked using Camshaft Adjuster Gauge T40030 .

Crankshaft secured using Locking Pin T40026 .

Camshaft gears loosened.

Note:

Replace seals, sealing rings, O-rings and self-locking bolts.

When turning camshaft, crankshaft must not be at TDC with any cylinder. Valves and/or pistons may be damaged.



Screw on camshaft gears - 1 to 4 - until they can just still be turned and do not tilt.

Place toothed belt as shown in illustration.

Toothed belt and all toothed belt gears must fit exactly on front edge for a precise valve timing adjustment.

Turn eccentric roller - 1 - using Pin Wrench 3387 clockwise until spanner wrench handle lies directly over coolant pump sprocket center axis - 2 - .

Hold Pin Wrench 3387 securely in this position and tighten screw - 3 - to 45 Nm.

Place torque wrench horizontally on tensioning lever hex socket.



Turn toothed belt to 45 Nm in direction of - arrow - to pre-tension.

Rotate toothed belt tensioning roller using 8mm hex socket in direction of - arrow - until Locking Pin T40011 can be removed.

Place torque wrench horizontally on tensioning lever hex socket.

Turn toothed belt to 25 Nm in direction of - arrow - to tension.



Place Socket T40028 on exhaust camshaft adjuster on left cylinder bank.

Rotate camshaft adjuster rotor clockwise to 10 Nm to stop - arrow - .

Rotate camshaft adjuster rotor on right cylinder bank clockwise to 10 Nm to stop - arrow- .

Tighten bolts for all four camshaft gears to 100 Nm.

Insert cover caps - 2 - with new O-rings - 1 - on camshaft gears and secure with circlip.



Note:

Ignore - 3 - .

Remove Camshaft Adjuster Gauge T40030 .

Remove crankshaft holder T10026 and install TDC mark sealing plugs with new O-ring in cylinder block.

The rest of the installation is performed in reverse order of removal, noting the following:

Install cylinder head covers. Refer to: Left Left Cylinder Head Cover , right Right Cylinder Head Cover .

Install toothed belt covers. Refer to Toothed Belt Covers Component Overview .

Install vibration damper. Refer to Vibration Damper .

Install ribbed belt tensioner. Refer to Ribbed Belt Tensioner .

Install ribbed belt. Refer to Ribbed Belt .

Install the lock carrier with attachments. Refer to Body Exterior - Repair Group 50 .

Install the front bumper cover. Refer to Body Exterior - Repair Group 63 .

Tightening Specifications

Copyright © 2008 Audi of America, Inc. and Bentley Publishers. All rights reserved. Last processed:

Component NmEccentric roller to front sealing flange 45Camshaft sprocket to camshaft 100Sealing plugs in cylinder block 25Belt pulley to power steering pump 23



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Audi > A4, S4 (B6, B7) > 2002 -2008 3.0 Liter 6-Cyl. 5V