How to Replace timing belt on Audi TT 2.0 TFSI 2009

Audi TT

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.

Valve timing procedures

How to Replace timing belt on Audi TT 2.0 TFSI 2009

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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