How to Replace timing belt on Audi A3 8P MK2 1.6 2005-2012

A3 Audi

Аudi А3 Cambelt Change Interval

  • →2003MY: No manufacturer’s recommended replacement interval.NOTE: Audi UK recommend the timing belt is replaced every 5 years.
  • 2004MY→: Audi recommend replacement every 75,000 miles or 5 years.
  • The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

 

  • CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur.

 

  • A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Remove & install2,20

Special Tools

  • Engine support – No.10-222A.
  • Two-pin wrench – No.T10020.

Special Precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove spark plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • DO NOT turn engine via camshaft or other sprockets.
  • Observe all tightening torques.
  • Removal

    1. Raise and support front of vehicle.
    2. Remove:
        • Engine undershield.
        • RH front wheel.
        • RH front inner wing panel.
        • Engine upper cover.
    3. Disconnect:
        • Vacuum pipe to evaporative emission (EVAP) canister.
        • Fuel supply pipe.
    4. Move evaporative emission (EVAP) canister to one side.
    5. Remove:
        • Evaporative emission (EVAP) canister bracket.
        • Windscreen washer reservoir filler neck.
    6. Disconnect coolant expansion tank multi-plug.
    7. Remove:
        • Coolant expansion tank. DO NOT disconnect hoses.
        • Auxiliary drive belt splash shield.
        • Auxiliary drive belt. Lock tensioner in position. Use Allen key.
        • Auxiliary drive belt tensioner.
        • Timing belt upper cover [1] .
    8. Turn crankshaft to TDC on No.1 cylinder.
    9. Ensure crankshaft pulley timing marks aligned [2] .
    10. Ensure camshaft sprocket timing marks aligned [3] .
    11. Remove:
        • Crankshaft pulley bolts [4] .
        • Crankshaft pulley [5] .
        • Timing belt centre cover [6] .
        • Timing belt lower cover [7] .
    12. Install engine support. Tool No.10-222A.
    13. Remove:
        • RH engine mounting bolts [8] [9] [10] .
        • RH engine mounting.
        • RH engine mounting bracket bolts [11] .
        • RH engine mounting bracket [12] .

      NOTE: Engine may need to be raised/lowered slightly.

    14. Slacken tensioner nut [13] . Turn tensioner clockwise away from belt. Use tool No.T10020 [14] . Lightly tighten nut [13] .
    15. Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

    Installation

    1. Ensure camshaft sprocket timing marks aligned [3] .
    2. Fit timing belt to crankshaft sprocket and water pump sprocket.
    3. Install:
        • Timing belt lower cover [7] .
        • Timing belt centre cover [6] .
        • Crankshaft pulley [5] .
        • Crankshaft pulley bolts [4] .
    4. Tighten crankshaft pulley bolts [4] . Tightening torque: 10 Nm + 90°. Use new bolts.
    5. Ensure crankshaft pulley timing marks aligned [2] .
    6. Fit timing belt to tensioner pulley and camshaft sprocket.NOTE: Ensure belt is taut between sprockets on non-tensioned side.
    7. Ensure tensioner retaining lug is properly engaged [15] .
    8. Slacken tensioner nut [13] .
    9. Turn tensioner twice fully anti-clockwise and clockwise from stop to stop. Use tool No.T10020 [14] .
    10. Turn tensioner anti-clockwise until pointer [16] aligned with notch [17] in baseplate. Use tool No.T10020 [14] .
    11. Tighten tensioner nut [13] . Tightening torque: 23 Nm.
    12. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.NOTE: Turn crankshaft last 45° smoothly without stopping.
    13. Ensure camshaft sprocket timing marks aligned [3] .
    14. Ensure crankshaft pulley timing marks aligned [2] .
    15. Ensure pointer [16] aligned with notch [17] in baseplate.
    16. If not: Repeat tensioning procedure.
    17. Apply firm thumb pressure to belt at . Pointer [16] and notch [17] must move apart.
    18. Release thumb pressure from belt at .
    19. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.NOTE: Turn crankshaft last 45° smoothly without stopping.
    20. Ensure camshaft sprocket timing marks aligned [3] .
    21. Ensure crankshaft pulley timing marks aligned [2] .
    22. Ensure pointer [16] aligned with notch [17] in baseplate.
    23. Install:
        • RH engine mounting bracket [12] .
        • RH engine mounting bracket bolts [11] .
    24. Tighten RH engine mounting bracket bolts [11] . Tightening torque: 45 Nm.
    25. Fit and align RH engine mounting:
        • Engine mounting clearance: 16 mm [18] .
        • Ensure engine mounting aligned parallel with engine mounting bracket [19] .
    26. Tighten:
        • Engine mounting bolts [9] . Tightening torque: 40 Nm + 90°. Use new bolts.
        • Engine mounting bolts [8] . Tightening torque: 20 Nm + 90°. Use new bolts.
        • Engine mounting bolts [10] . Tightening torque: 60 Nm + 90°. Use new bolts.
    27. Install components in reverse order of removal.NOTE: The manufacturer recommends bleeding the fuel system before starting engine.
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Bent Valves
Timing Tools?
Misconception
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Bent Valves

What happens when your chain or belt breaks. 

The timing of course becomes way off. Your crankshaft will always spin making the pistons move up and down. However the valves will remain in the position they were in when the belt or chain stopped working. 

Half of the valves will be stuck open and in the way of the pistons. Not all engines, but most. The piston out of valve time will smash right into the open valve and bend the, The only way to fix that is to remove the head and place those valves. 

If you think your valves might have been damaged.

Remove all the spark plugs, valve covers. With both valves in the closed position insert a compression tester hose in place of the spark plug and inject air into the hose and see if the cylinder can hold air. If both valve are closed and air can not be held, chances are you have bent valves.   

 

Timing Tools?

Do you need special tools to time your engine? Not always, on all my post I'll indicate that in each post if you do or not. 

But what are these special tools? Normally you would just line up some marks on the cam and crank gears and simply be done with it. However when these tools are needed they are very very important. 

The last one I did was a 2013 Range Rover 2.0 Turbo with dual cams. There were not timing marks at all. 

There is a small threaded plug on the back of the engine that I removed to insert a special threaded pin that would rest up against the weight of the crankshaft to prevent for DTC of the #1 piston. No further clockwise rotation would be possible. At that point I installed the supplied crankshaft lock by removing the starter. 

Then you line up the back of both camshafts to a notch in each camshafts to each other that a flat tool connects to each cam so they are in line with each other. But first you would make sure both intake and exhaust valves are closed DTC of the cams. 

And the last tool was to lineup the crankshaft position sensor. 

 

Misconception

The most important thing in any major engine work is to rotate the engine by hand at least two complete rotations. And do it easy and slow and with the spark plugs removed. 

Why remove the spark plugs? you may ask. Simple, with the plugs in place you'll be creating compression, making the engine harder to turn by hand and perhaps giving you the misconception of valves hitting the pistons or is it compression.  

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