How to Replace timing belt on Audi A3 8P MK2 2.0 TFSI quattro 2005-2008

A3 Audi Quattro

Replacement Interval Guide

  • Audi recommend:
  • →2003MY: Replacement every 115,000 miles.NOTE: Audi UK recommend the timing belt is replaced every 5 years.
  • 2004MY→: 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 & install:
A32,50
S32,90
TT3,70

Special Tools

  • Auxiliary drive belt tensioner locking pin – Audi No.T10060A.
  • Two-pin wrench – Audi No.T10020.
  • Auxiliary drive belt tensioner tool – Audi No.U40050.

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.
How to Replace timing belt on Audi A3 2.0 TFSI quattro 2005-2008

Removal

  1. Raise and support front of vehicle.
  2. Remove:
      • Engine undershield.
      • RH front wheel.
      • RH front inner wing panel.
      • Engine top cover.
      • S3: Turbocharger lower air duct.
      • S3: Engine lower tie-bar.
  3. Drain cooling system.
  4. Disconnect:
      • Fuel vapour hose from evaporative emission (EVAP) canister.
      • Fuel supply and return pipes.
  5. Move evaporative emission (EVAP) canister to one side.
  6. Remove:
      • Evaporative emission (EVAP) canister bracket.
      • Windscreen washer reservoir filler neck.
  7. Disconnect coolant expansion tank multi-plug.
  8. Disconnect coolant hose from timing belt upper cover.
  9. TT: Unclip coolant expansion tank lower hose.
  10. Remove:
      • Coolant expansion tank. DO NOT disconnect hoses.
      • With AC: Auxiliary drive belt. Use tool No.T10060A.
      • With AC: Auxiliary drive belt tensioner.
      • Without AC: Auxiliary drive belt. Use tool No.U40050.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

  11. Support engine.NOTE: Remove auxiliary drive belt tensioner locking pin No.T10060A before removing RH engine mounting.
  12. Remove:
      • RH engine mounting [1] .
      • RH engine mounting bracket bolts [2] .
      • RH engine mounting bracket [3] .

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

  13. Remove timing belt upper cover inspection plate [4] .
  14. Turn crankshaft clockwise to TDC on No.1 cylinder.
  15. Ensure timing marks aligned [5] [6] .
  16. Remove:
      • Crankshaft pulley bolts [7] .
      • Crankshaft pulley [8] .
      • Timing belt upper cover [9] .
      • Timing belt lower cover [10] .
  17. Slacken tensioner pulley nut [11] .
  18. Turn tensioner pulley clockwise away from belt. Use tool No.T10020 [12] or Allen key. Lightly tighten nut [11] .
  19. Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: Engine must be COLD.

  1. Check tensioner pulley and guide pulleys for smooth operation. Replace if necessary.
  2. Ensure camshaft sprocket timing marks aligned [6] .
  3. Fit timing belt to crankshaft sprocket.NOTE: If reusing old belt, observe direction of rotation marks on belt.
  4. Install:
      • Timing belt lower cover [10] .
      • Crankshaft pulley [8] .
      • Crankshaft pulley bolts [7] . Use new bolts.
  5. Tighten crankshaft pulley bolts [7] . Tightening torque: 10 Nm + 90°.
  6. Ensure crankshaft pulley timing marks aligned [5] .
  7. Fit timing belt in following order:
      • Guide pulley (G1).
      • Tensioner pulley.
      • Camshaft sprocket.
      • Water pump sprocket.
      • Guide pulley (G2).

    NOTE: Ensure belt is taut between sprockets on non-tensioned side.

  8. Ensure retaining lug located in slot in cylinder head [13] .
  9. Slacken tensioner pulley nut [11] .
  10. Turn tensioner pulley clockwise until notch [14] is above lug [15] in baseplate. Use tool No.T10020 [12] or Allen key.
  11. Turn tensioner pulley anti-clockwise to release tension on belt. Use tool No.T10020 [12] or Allen key.
  12. Turn tensioner pulley clockwise until notch aligned with lug in baseplate [15] [16] . Use tool No.T10020 [12] or Allen key.
  13. Tighten tensioner pulley nut [11] . Tightening torque: 25 Nm.
  14. Turn crankshaft slowly two turns clockwise until timing marks aligned [5] [6] .NOTE: Turn crankshaft last 45° smoothly without stopping.
  15. Ensure notch aligned with lug in baseplate [16] [15] .
  16. If not: Repeat tensioning procedure.
  17. Install:
      • Timing belt upper cover [9] .
      • RH engine mounting bracket [3] .
      • RH engine mounting bracket bolts [2] .
  18. Tighten RH engine mounting bracket bolts [2] . Tightening torque: 40 Nm.
  19. Lower engine slightly.
  20. Fit and align RH engine mounting [1] :
      • Engine mounting clearance: 16 mm [17] .
      • Ensure engine mounting aligned parallel with engine mounting bracket [18] .
  21. Tighten:
      • Engine mounting bolts [19] . Tightening torque: 40 Nm + 90°. Use new bolts.
      • Engine mounting bolts [20] . Tightening torque: 20 Nm + 90°. Use new bolts.
      • Engine mounting bolts [21] . Tightening torque: 60 Nm + 90°. Use new bolts.
  22. Install components in reverse order of removal.
  23. Refill cooling system.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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