How to Replace timing belt on Audi A3 8P MK2 1.6 TDI 2009

A3 Audi

Replacement Interval Guide

  • 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 ‚Äď hrs

Remove & install:
A12,70
A32,20

Special Tools

  • Camshaft sprocket/high-pressure fuel pump sprocket holding tool ‚Äď No.T10172/2.
  • Camshaft/high-pressure fuel pump locking tool ‚Äď 2 x No.3359.
  • Crankshaft sprocket locking tool ‚Äď No.T10050.
  • Multi-spline socket ‚Äď No.T10385.
  • Tensioner pulley adjusting tool ‚Äď No.T10264 or T10409.
  • Tensioner pulley locking tool ‚Äď No.T10265.

Special Precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove glow 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.
How to Replace timing belt on Audi A3 1.6 TDI 2009-

Removal

  1. Raise and support front of vehicle.
  2. Remove engine top cover.
  3. Disconnect diesel particulate filter (DPF) pressure sensor multi-plug.
  4. Remove diesel particulate filter (DPF) pressure sensor bracket.
  5. Disconnect:
      • Fuel supply and return pipes.
      • Fuel pre-heater valve.
  6. Remove fuel filter. DO NOT disconnect hoses.
  7. Disconnect coolant level sensor multi-plug.
  8. A1: Move coolant expansion tank to one side. DO NOT disconnect hoses.
  9. Disconnect engine coolant temperature (ECT) sensor multi-plug.
  10. Detach coolant pipe support bracket from engine mounting bracket. DO NOT disconnect hoses.
  11. Remove timing belt upper cover [1] .
  12. Remove:
      • RH front wheel.
      • RH wheel arch liner.
      • Engine undershield.
      • Auxiliary drive belt.
      • Crankshaft pulley bolts¬†[2]¬†.
      • Crankshaft pulley¬†[3]¬†.
  13. A1: Support engine.
  14. Remove:
      • Timing belt lower cover¬†[4]¬†.
      • A1: RH engine mounting.
      • A1: RH engine mounting bracket.
  15. Turn crankshaft clockwise to TDC on No.1 cylinder.
  16. Lock camshaft [5] . Use tool No.3359.
  17. Lock crankshaft sprocket [6] . Use tool No.T10050.
  18. Ensure timing marks aligned [7] .
  19. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [8] .
  20. Slacken camshaft sprocket bolts [9] .
  21. Slacken high-pressure fuel pump sprocket bolts [10] . Use tool No.T10385.NOTE: There are two types of tensioner pulley.
  22. Tensioner pulley type A:
      • Slacken tensioner pulley nut¬†[11]¬†.
      • Turn tensioner pulley anti-clockwise until locking tool can be inserted¬†[12]¬†. Use tool No.T10264¬†[13]¬†.
      • Insert locking tool in tensioner pulley¬†[14]¬†. Tool No.T10265.
      • Turn tensioner pulley fully clockwise until it reaches stop¬†[15]¬†. Use tool No.T10264¬†[13]¬†.
      • Tighten tensioner pulley nut finger tight¬†[11]¬†.
  23. Tensioner pulley type B:
      • Slacken tensioner pulley nut¬†[16]¬†.
      • Turn tensioner pulley clockwise to release tension on belt. Use tool No.T10409¬†[17]¬†.
      • Tighten tensioner pulley nut finger tight¬†[16]¬†.
  24. Remove timing belt, starting at guide pulley (G3).NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: Engine must be COLD.

  1. Ensure camshaft locked with tool [5] .
  2. Tighten camshaft sprocket bolts finger tight [9] .
  3. Fit new high-pressure fuel pump sprocket bolts [10] . Tighten bolts finger tight.NOTE: Sprockets should turn freely but not tilt.
  4. Ensure crankshaft sprocket locking tool located correctly [6] & [8] .
  5. Lock high-pressure fuel pump [18] . Use tool No.3359.
  6. Turn camshaft sprocket fully clockwise in slotted holes.
  7. Turn high-pressure fuel pump sprocket fully clockwise in slotted holes.
  8. Fit timing belt in following order:
      • Crankshaft sprocket.
      • Guide pulley (G1).
      • Tensioner pulley.
      • Camshaft sprocket.
      • Water pump sprocket.
      • Guide pulley (G3).
      • High-pressure fuel pump sprocket.
      • Guide pulley (G2).
  9. Turn camshaft sprocket anti-clockwise to remove slack from belt between camshaft sprocket and high-pressure fuel pump sprocket. Use tool No.T10172/2.
  10. Hold camshaft sprocket.
  11. Tighten camshaft sprocket and high-pressure fuel pump sprocket bolts [9] & [10] . Tightening torque: 20 Nm.
  12. Tensioner pulley type A:
      • Slacken tensioner pulley nut¬†[11]¬†.
      • Remove locking tool from tensioner pulley¬†[14]¬†.
      • Ensure tensioner pulley retaining lug is properly engaged¬†[19]¬†.
      • Turn tensioner pulley slowly clockwise until pointer aligned with notch¬†[20]¬†.NOTE: Ensure tensioner pulley nut does not turn¬†[11]¬†.
      • Hold tensioner pulley. Use tool No.T10264¬†[13]¬†.
      • Tighten tensioner pulley nut¬†[11]¬†. Tightening torque: 20 Nm + 45¬į.
  13. Tensioner pulley type B:
      • Slacken tensioner pulley nut¬†[16]¬†.
      • Turn tensioner pulley anti-clockwise until pointer aligned with notch¬†[21]¬†&¬†[22]¬†. Use tool No.T10409¬†[17]¬†.NOTE: Ensure tensioner pulley nut does not turn¬†[16]¬†.
      • Hold tensioner pulley. Use tool No.T10409¬†[17]¬†.
      • Tighten tensioner pulley nut¬†[16]¬†. Tightening torque: 20 Nm + 45¬į.
  14. Remove:
      • Camshaft locking tool¬†[5]¬†.
      • High-pressure fuel pump locking tool¬†[18]¬†.
      • Crankshaft sprocket locking tool¬†[6]¬†.
  15. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
  16. Fit crankshaft sprocket locking tool while slowly turning crankshaft to TDC [6] .
  17. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [8] .
  18. Ensure timing marks aligned [7] .
  19. Ensure camshaft locking tool can be inserted easily [5] .NOTE: DO NOT insert high-pressure fuel pump locking tool as alignment hole may be slightly misaligned. No adjustment required.
  20. Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the left or right of notch [20] or [22] . If not: Repeat tensioning procedure.
  21. If camshaft locking tool cannot be inserted easily [5] :
      • Remove lug of crankshaft sprocket locking tool from hole in oil seal housing.
      • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing¬†[23]¬†.
      • Turn crankshaft clockwise until camshaft locking tool can be inserted¬†[5]¬†.
      • Slacken camshaft sprocket bolts¬†[9]¬†.NOTE: Lug of crankshaft sprocket locking tool will be positioned to the left or right of hole in oil seal housing.
  22. If lug of crankshaft sprocket locking tool is positioned to the left of hole in oil seal housing:
      • Turn crankshaft clockwise until lug and hole aligned¬†[8]¬†.
      • Lock crankshaft sprocket¬†[6]¬†.
      • Ensure timing marks aligned¬†[7]¬†.
      • Tighten camshaft sprocket bolts¬†[9]¬†. Tightening torque: 20 Nm.
  23. If lug of crankshaft sprocket locking tool is positioned to the right of hole in oil seal housing:
      • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing¬†[23]¬†.
      • Turn crankshaft clockwise until lug and hole aligned¬†[8]¬†.
      • Lock crankshaft sprocket¬†[6]¬†.
      • Ensure timing marks aligned¬†[7]¬†.
      • Tighten camshaft sprocket bolts¬†[9]¬†. Tightening torque: 20 Nm.
  24. Remove locking tools [5] & [6] .
  25. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
  26. Lock crankshaft sprocket [6] .
  27. Ensure timing marks aligned [7] .
  28. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [8] .
  29. Ensure camshaft locking tool can be inserted easily [5] .
  30. Hold camshaft sprocket. Use tool No.T10172/2.
  31. Tighten camshaft sprocket bolts [5] . Tightening torque: 25 Nm.
  32. Hold high-pressure fuel pump sprocket. Use tool No.T10172/2.
  33. Tighten high-pressure fuel pump sprocket bolts [10] . Tightening torque:
      • A ‚Äď A1: 20 Nm + 90¬į.
      • B ‚Äď A3: 20 Nm.
  34. Remove locking tools [5] & [6] .
  35. Install components in reverse order of removal.
  36. Tighten crankshaft pulley bolts¬†[2]¬†. Tightening torque: 10 Nm + 90¬į. Use new bolts.
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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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