1997AudiA6Quatro2.8L-aligning cam and crankshaft for timing belt

Remove the spark plugs and measuring the distance through the plug holes with a rod, very gently turn the crankshaft (either way) until you are certain all the pistons are well below tdc and then gently bring the camshaft(s) to the timing position, followed by bringing the crank to the timing position.

Standby, having trouble posting

1. Remove all spark plugs so that the crank shaft could be rotated easily.
2. Rotate the crankshaft to align the timing mark of the crankshaft gear with the index mark on the engine cover.
3.Rotate the crankshaft +/- 30 degrees to ensure that the valve could not hit the pistons when aligning the camshaft gears.
4. Align the camshafts as described below.
5. Align the crankshaft timing gear with the index mark.
6. Loose and lock the timing bearing at its farther position. Install a timing belt starting from the crankshaft gear, then right cam, then left cam, and at last the timing bearing.
7. Press and hold the timing belt to keep it firm on the gears and loosen the timing bearing. It will get adjusted by itself with the help of spring attached to it. Do not put extra force on the bearing to adjust it more.
8. Confirm the timing marks.

Arrows point to timing marks in correct position.

Installation
1.Install No. 2 idler pulley (if removed). Install and tighten bolt to specification. See TORQUE SPECIFICATIONS . Ensure idler pulley is clean and rotates smoothly. 2.Install No. 1 idler pulley and tension spring (if removed). Pry No. 1 idler pulley away from timing belt area as far as possible. Temporarily tighten No. 1 idler pulley bolt. Ensure idler pulley is clean and rotates smoothly. 3.Using crankshaft pulley bolt, rotate crankshaft so timing mark on crankshaft sprocket aligns with timing mark on oil pump housing. See. This will position keyway in crankshaft sprocket at 12 o'clock position.

CAUTION:If reusing timing belt, ensure reference marks on timing belt align with reference marks placed on crankshaft and camshaft sprockets. Ensure timing belt is installed in original direction of rotation.
4.Ensure all sprockets and idler pulleys are clean. Install timing belt on crankshaft sprocket, oil pump sprocket, No. 1 idler pulley, and then No. 2 idler pulley in sequence. 5.Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install No. 1 timing belt cover and new gasket. 6.Align crankshaft pulley key groove with key in crankshaft. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. 7.Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover. If reusing timing belt, ensure reference mark on timing belt aligns with upper edge of No. 1 timing belt cover. 8.Rotate camshaft, and align hole in camshaft sprocket with alignment mark on camshaft bearing cap. See Fig. 2 . Install timing belt on camshaft sprocket. If reusing timing belt, ensure reference mark on timing belt aligns with the reference mark on camshaft sprocket. Ensure tension exists on timing belt between the crankshaft and camshaft sprockets.
CAUTION:DO NOT rotate crankshaft counterclockwise, as viewed from timing belt end of engine.
9.Loosen No. 1 idler pulley bolt 1/2 turn. Rotate crankshaft pulley 2 full revolutions clockwise from TDC to TDC. 10.Ensure timing mark on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover, and hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 2 . If timing marks are not aligned, remove timing belt and reinstall. 11.Rotate crankshaft clockwise 1 and 7/8 revolutions and align crankshaft pulley "0" mark with 45-degree Before Top Dead Center (BTDC) mark on No. 1 timing belt cover. See Fig. 5 . 12.Tighten No. 1 idler pulley bolt to specification. See TORQUE SPECIFICATIONS . Install No. 2 timing belt cover and gaskets. Install and tighten spark plugs to specification. 13.To install remaining components, reverse removal procedure. Install all bolts/nuts on right (timing belt side) engine mount before tightening to specification. 14.On Camry, when installing control rod and bracket on strut tower and right (timing belt side engine mount, tighten bolts to specification in sequence.

Timing Belt Cover, Belt & Sprockets Removal & Installation 2.5L Engine To Remove:

1. Remove the drive belts.
2. Remove the A/C compressor drive belt tensioner. Timing belt & cover DOHC exploded view
   
   
3. Remove the crankshaft pulley.
4. Remove the mounting bolts and left timing belt cover.
5. Remove the mounting bolts and right timing belt cover.
6. Remove the mounting bolts and front timing belt cover.
7. Vehicles W/ M/T: Remove the timing belt guide.
8. Ensure that the timing belt rotation arrows are still visible. If the marks are worn off, place new rotation marks on the belt. Timing belt alignment marks DOHC
   
   
9. Turn the crankshaft using a breaker bar and special adapter socket on the crankshaft. Align the timing mark on the crankshaft sprocket (1), left intake sprocket (2), left exhaust sprocket (3), right intake sprocket (4) and right exhaust sprocket (5) with the notches in cylinder block and timing belt cover.
10. Paint alignment marks on the timing belt at the crankshaft and camshaft sprockets timing marks. CAUTION
    Do not turn the camshaft sprockets with the timing belt removed. The valves heads will contact each other causing the valve stems to bend.
    
11. Remove the lower right idler pulley.
12. Remove the timing belt.
13. Remove the upper right idler pulley.
14. Remove the lower left (toothed) idler pulley.
15. Remove the belt tensioner.
16. Hold the sprocket and remove the left intake and exhaust camshafts.
17. Hold the sprocket and remove the right intake and exhaust camshafts.
18. Remove the crankshaft sprocket.

To Install:

1. Install the crankshaft sprocket.
2. Hold the sprocket and install the right intake and exhaust camshafts with the mounting bolts. Tighten 58 ft-lb (78 Nm).
3. Hold the sprocket and install the left intake and exhaust camshafts with the mounting bolts. Tighten 58 ft-lb (78 Nm).
4. Reset the automatic belt tensioner as follows:
   • Remove the mounting bolt and belt tensioner. NOTE: Do not exceed more than 2,205 lb. (9,807 N).
     
   • Place the belt tensioner on a press. Press the adjuster rod down gradually (using more than 3 minutes) 66- lb (165 N) or more until the adjuster rod is aligned with the stop pin hole in the cylinder.
   • Insert a 0.08 in (2 mm) diameter pin or hex wrench into the pin hole to lock the adjuster rod.
   • Install the automatic belt tension adjuster with the mounting bolt. Tighten 18 ft-lb (25 Nm).
5. Install the lower left (toothed) idler pulley. Tighten 29 ft-lb (39 Nm).
6. Install the upper right idler pulley with the mounting bolt. Tighten 29 ft-lb (39 Nm). Crankshaft sprocket and oil pump cover alignment marks 2.5L DOHC
   
   
7. Align the timing mark on the crankshaft sprocket with the mark on the oil pump cover. Timing belt alignment marks DOHC
   
   
8. Align the single timing mark on the right exhaust camshaft sprocket with the notch on the timing belt cover.
9. When the single timing mark on the right exhaust camshaft sprocket is aligned with the notch on the timing belt cover, ensure that the double lines on the intake camshaft and exhaust camshaft sprockets are aligned.
10. Align the single timing mark on the left exhaust camshaft sprocket with the notch on the timing belt cover by turning the sprocket counter clockwise (viewed from front of engine).
11. Ensure that the double lines on the intake camshaft and exhaust camshaft sprockets are aligned when the single timing mark on the left exhaust camshaft sprocket is aligned with the notch on the timing belt cover. CAUTION
    • The camshafts can be rotated independently causing the valves heads to contact each other resulting in bent valve stems.
    • When the timing belt is removed the camshafts will turn to the lowest cam lobe position by the force of the valve springs. Before installing the timing belt the 4 camshafts are in the lowest lift position (valves closed).
    • When the camshafts are rotated to install the timing belts, # 2 intake and # 4 exhaust cam lobes of the left camshafts are held to push their corresponding valves down. In this position, these valves are held in the open position. Right camshafts are held so their cam lobes do not push the valves down.
    • The left camshafts must be rotated from the lowest lobe position to the position where the timing belt can be installed at the smallest possible angle in order to prevent intake and exhaust valve contact. Camshaft sprockets rotation
      
      
    • Do not turn the camshafts in the direction shown in the illustration because the valves will open at the same time and contact each other.
    CAUTION
    If the timing belt alignment is off the mark buy more than 3 teeth, the valves and pistons may have contact.
    Timing belt alignment marks DOHC
    
    
12. Align the timing marks on the belt with the marks on the sprockets in the numerical order shown in the illustration.
13. Install the lower right idler pulley with the mounting bolt. Tighten 29 ft-lb (39 Nm).
14. Ensure that the timing mark alignment is correct and remove the tensioner stop pin.
15. Vehicles W/ M/T: Install the timing belt guide and temporarily tighten the mounting bolts.
16. Vehicles W/ M/T: Measure the clearance between the guide and timing belt. The clearance should measure 0.039 ± 0.020 in (1.0 ± 0.5 mm).
17. Vehicles W/ M/T: Tighten the guide bolts 7.2 ft-lb (9.8 Nm).
18. Install and secure the front timing belt cover with the mounting bolts.
19. Install and secure the right timing belt cover with the mounting bolts.
20. Install and secure the left timing belt cover with the mounting bolts.
21. Install the crankshaft pulley.
22. Install the A/C compressor drive belt tensioner.
23. Install the drive belts.

hi, here is a guide i have come across on this site written by another expert it should be the one for your engine but always double check.

If you are unsure what you are doing then please go out and buy a haines workshop manual as these tell you every detail you need to know so that would be your best solution.

Please dont do this work if your unsure what you are doing as you could damage the engine beyond repair so you have been warned;

it covers single cam and if you scroll down it shows double cam ok

Sep 14, 2009 - VW Passat & Audi A4 1990-2000 Repair Guide
Timing Belt - REMOVAL & INSTALLATION

2.8L SOHC (AFC) V6 Engine

1. Note the radio security code and disconnect the negative battery cable.
2. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
3. Remove the engine accessory drive belt. For additional information, please refer to the following topic(s): General Information And Maintenance, Routing Maintenance And Tune-up.
4. Turn the engine by hand to Top Dead Center (TDC) on the firing stroke for cylinder No. 1.

NOTE The large holes in the camshaft sprocket lock plates should be on the inside facing one another.

1. Remove the Crankshaft Position (CKP) sensor from the lower left side of the engine block. Make sure the engine is at TDC and install the threaded crankshaft holding pin Tool No. 3242 and lightly tighten.
2. Remove the upper timing belt covers, the crankshaft vibration damper and then the lower timing belt cover.
3. Loosen the camshaft sprocket bolts slightly and use a suitable pulley to release the sprockets from the tapered ends of the camshafts.
4. Loosen the tensioner roller and remove the drive belt.

To install :

1. Install the timing belt over the sprockets, then the idler rollers and lastly over the tensioner.
2. Install camshaft alignment tool holder Tool No. 3243 into the camshaft alignment flanges.
3. Check and adjust the cam belt tension such that the upper left portion of the belt between the tensioner and the left cam gear can just be twisted 90° ( 1 / 4 turn).
4. Tighten the cam belt tensioning roller to 33 ft. lbs. (45 Nm), and the camshaft sprocket bolts.
5. The balance of the installation is in reverse order of removal.

2.8L DOHC 5V (AHA) V6 Engine

1. Note the radio security code and disconnect the negative battery cable.
2. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
3. Remove the engine accessory drive belt. For additional information, please refer to the following topic(s): General Information And Maintenance, Routing Maintenance And Tune-up.
4. Turn the engine by hand to Top Dead Center (TDC) on the firing stroke for cylinder No. 1.

NOTE The large holes in the camshaft sprocket lock plates should be on the inside facing one another.

1. On the cylinder block near the crankshaft, remove the sealing plug from the lower left side of the engine block. Make sure the engine is at TDC and install the threaded crankshaft holding pin Tool No. 3242 and lightly tighten.
2. Remove the upper timing belt covers, the crankshaft vibration damper and then the lower timing belt cover.
3. Loosen the camshaft sprocket bolts slightly and use a suitable pulley to release the sprockets from the tapered ends of the camshafts.
4. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, insert a 2mm spring pin through the tensioner housing and tensioner plunger to secure it in place. When the plunger is secure, release the wrench tension.
5. Remove the damper-to-crankshaft bolts and the damper.

NOTE It is not necessary to remove the center bolt when removing the crankshaft damper.

1. Remove the serpentine belt idler and the crankshaft damper guard.
2. Mark the running direction of the timing belt and remove it from the pulleys.

Fig. Crankshaft pulley alignment location for TDC-Audi 2.8L V6 engines




Fig. Left camshaft sprocket alignment position for TDC; right camshaft position is similar-Audi 2.8L V6 engines




Fig. View of crankshaft holding tool installed-Audi 2.8L V6 engines




Fig. View of camshaft locator bar installed-Audi 2.8L V6 engines


To install:

1. Make sure that the camshaft pulleys and the crankshaft pulley are in alignment with TDC of the No. 1 cylinder's compression stroke.
2. Install the timing belt; make sure the timing belt is installed in the correct running direction from which it was removed.
3. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, remove the 2mm spring pin from the tensioner housing. Slowly, release the tensioner spring pressure to put pressure on the timing belt.
4. Install the crankshaft damper guard and the serpentine belt idler pulley; torque the idler pulley bolts to 33 ft. lbs. (45 Nm).
5. Install the crankshaft damper and torque the damper-to-crankshaft bolts to 15 ft. lbs. If the damper-to-crankshaft center bolt was removed, torque it to 147 ft. lbs. (200 Nm) plus 180° 1 / 2 turn).
6. Remove the Crankshaft Holder tool No. 3242 and install the sealing plug.
7. Replace the remaining components by reversing the removal procedures.
8. Refill the cooling system and the automatic transaxle. Connect the electrical connectors. Install the negative battery cable last.
9. Test drive the vehicle.

Fig. 1: Timing marks are located on the camshaft pulleys as shown-1.8L engines



Fig. 2: Make sure that the crankshaft sprocket (timing belt pulley) and oil pump timing marks are aligned-1.8L engines



Fig. 3: Align the timing belt pulley mark with the tension set mark, at approximately the 10 o'clock position-1.8L engines



I hope helps with this (reemmber rated this help) Good luck.

Ford Escort/Tracer 1991-1999 Repair Guide

REMOVAL & INSTALLATION 1.8L Engine
(see Figures 1, 2, 3 and 4)

1. Disconnect the negative battery cable.
2. Remove the timing belt covers.
3. Rotate the crankshaft and align the timing marks located on the camshaft pulleys and the seal plate.
4. Remove the crankshaft pulley and hub.
5. If the timing belt is to be reused, mark an arrow on the belt to indicate its rotational direction to enable correct re-installation.
6. Loosen the timing belt tensioner lockbolt and remove the timing belt.

To install:

1. Temporarily secure the timing belt tensioner in the far left position with the spring fully extended, then tighten the lockbolt.
2. Make sure the timing marks on the timing belt pulley (crankshaft sprocket) and the engine block (oil pump housing) are aligned.
3. Make sure the timing marks on the camshaft pulleys and the seal plate are aligned.
4. Install the timing belt.
5. Loosen the tensioner lockbolt. Using a suitable prying tool, position the timing belt tensioner so the timing belt is taut, then tighten the tensioner lockbolt.
6. Turn the crankshaft two turns clockwise and align the timing belt pulley mark with the mark on the engine block.

Fig. 1: Timing marks are located on the camshaft pulleys as shown-1.8L engines



Fig. 2: Make sure that the crankshaft sprocket (timing belt pulley) and oil pump timing marks are aligned-1.8L engines



Fig. 3: Align the timing belt pulley mark with the tension set mark, at approximately the 10 o'clock position-1.8L engines


Fig. 4: Check the timing belt deflection at the location shown-1.8L engines

1. Make sure the camshaft pulley marks are aligned with the seal plate marks.

If the timing marks are not aligned, remove the belt and repeat the procedure.


I hope help you with this; remember rated this help. Good luck.

A factory service manual would help, but I'm assuming that if you had one, you probably wouldn't be on this site.

To set the timing, you need to first perform the obvious: remove the accessory drive belts, cam pulley covers, and engine fan and hub. Next you'll need to rotate the engine by hand until the timing marks on the camshaft sprockets and crankshaft are aligned with their corresponding stationary marks. The 0 degree mark on the lower timing belt cover is the timing mark for the crankshaft pulley. There is a mark (small, vertical formed indentation) for the left camshaft pulley on the backing plate behind the pulley near the 1 o` clock position. The same mark exists for the right camshaft pulley only it is on the backing plate near the 8 o`clock position (making it difficult to see). With the crankshaft placed at the zero mark, you can observed where the timing discrepancy exists.

(TIP: Once the right camshaft timing is properly lined up, etch an additional mark on the pulley's face and the backing plate at the 12 o`clock position. This will make it easier to align the pulley for furture adjustments and repairs)

To set the timing correctly, move the crankshaft pulley to 12 deg. BTDC. Being careful to not disturb the position of the crankshaft once it has been moved to that position, remove the crankshaft pulley, lower timing belt cover, timing belt tensioner, and timing belt. Compress the timing belt tensioner and if the original ring pin isn't available to retain the tensioner a small allen wrench can be used to achieve the same results. Line up both camshaft marks and reinstall the timing belt and timing belt tensioner (do not remove the timing belt tensioner tool used to maintain the tensioner piston in a compressed position). When installing the timing belt, be sure to allow the least amount of slack to exisit between the left camshaft pulley and the crankshaft sprocket, but without moving the pulleys.

Next, remove the timing belt tensioner piston retention tool and mount the lower timing belt cover and crankshaft pulley (without fully installing them). Rotate the crankshaft pulley to the 0 deg. mark. If done correctly, moving the crankshaft pulley from 12 deg. BTDC to 0 deg. will remove all remaining slack from the timing belt assembly and the camshaft pulleys and crankshaft pulleys will be lined up with their corresponding marks. Once proper timing has been achieved, install all removed parts.

(Another TIP: I hope it's not necessary, but in case it is, I'll remind you that proper torque of all bolts are necessary as this is an all aluminum engine. Stripping out bolts holes due to over-tightening bolts occurs very easily and become very annoying to deal with [e.g. alternator belts not being able to be tightened completely and constantly squealing every few days, etc.])