How to Replace timing chain on Audi A3 8P MK2 1.4 TFSI 2007-2012

A3 Audi

Special tools

  • Camshaft alignment tool – No.T10171A.
  • Camshaft sprocket holding tool – No.T10172.
  • Crankshaft pulley holding tool 1 – No.3415.
  • Crankshaft pulley holding tool 2 – No.3415/1.
  • Crankshaft timing pin – No.T10340.
  • Dial gauge – No.VAS 6079.
  • Dial gauge holder – No.T10170.
  • Tensioner locking tool – No.T40011.

General precautions

  • Disconnect battery earth lead.
  • Remove spark plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • Observe tightening torques.
  • If fitted: Mark position of crankshaft position (CKP) sensor before removal.
  • Do NOT turn crankshaft via camshaft or other sprockets.
  • Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

  • Removal/installation of timing chain requires:
      • Timing chain cover removal.
      • Sump removal.
  • Install dial gauge and holder in No.1 cylinder plug hole. Ensure engine at TDC on No.1 cylinder [1] .
  • Ensure timing marks on camshafts aligned as shown [2] . If not, turn crankshaft 360°.
  • Fit camshaft alignment tool [3] .

NOTE: If camshaft alignment tool cannot be inserted valve timing is incorrect.

  • Install crankshaft timing pin [4] .
  • Refit crankshaft pulley bolt with spacer. Finger tighten bolt.
  • Push tensioner rail against chain tensioner.
  • Fit tensioner locking tool [5] .

NOTE: If reusing timing chain: Mark direction of rotation on chains.

  • Remove camshaft alignment tool [3] .
  • Slacken bolt of each camshaft sprocket.

NOTE: Inlet camshaft sprocket bolt has LH thread.

  • Remove exhaust camshaft sprocket [6] and timing chain.
  • Align camshafts. Use special tool [3] .
  • Ensure crankshaft at TDC on No.1 cylinder:
      • Turn crankshaft slowly clockwise until it stops against timing pin [4] .
  • Install exhaust camshaft sprocket [6] with timing chain.
  • Renew bolt of each camshaft sprocket and re-tighten by hand.
  • Ensure camshaft sprockets turn freely but do not tilt.
  • Remove tensioner locking tool [5] .
  • Ensure crankshaft at TDC on No.1 cylinder:
      • Turn crankshaft slowly clockwise until it stops against timing pin.
  • Ensure camshaft alignment tool correctly located [3] .
  • Temporarily tighten camshaft sprocket bolts to:
      • Inlet camshaft sprocket bolt. Tightening torque: 40 Nm.
      • Exhaust camshaft sprocket bolt. Tightening torque: 50 Nm.
  • Remove camshaft alignment tool [3] .
  • Remove crankshaft timing pin [4] .
  • Turn crankshaft two turns clockwise.
  • Check engine at TDC on No.1 cylinder. Use dial gauge [1] .
  • Fit crankshaft timing pin [4] .
  • Ensure camshaft alignment tool can be fitted [3] .
  • If camshaft alignment tool cannot be fitted valve timing is incorrect. Repeat installation procedures.
  • Remove camshaft alignment tool [3] .
  • Remove crankshaft timing pin [4] .
  • Tighten camshaft sprocket bolts a further 90°.
  • Turn crankshaft two turns clockwise.
  • Check valve timing.
  • Tighten crankshaft pulley bolt. Tightening torque: 150 Nm + 180°.

NOTE: Crankshaft pulley bolt and bolt on each camshaft sprocket MUST only be used once.

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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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