How to Replace timing belt on Audi TT 2.0 TFSI 2009

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

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.