How to Replace timing chain on Audi A3 8P MK2 1.6 FSI 2005-2007

Special tools

• Camshaft alignment tool – Tool No.T10171.
• Dial gauge – Tool No.VAS 6079.
• Dial gauge holder – Tool No.T10170.
• Tensioner locking tool – Tool No.T40011.
• Crankshaft pulley/camshaft sprocket holding tool – Tool No.T10172.

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. If not, turn crankshaft 360° [2] .
  • Fit camshaft alignment tool [3] .
    

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

  • Fit tensioner locking tool [4] .
  • Remove camshaft sprockets and chain.NOTE: Inlet camshaft sprocket bolt has LH thread.
  • Align camshafts. Use special tool [3] .
  • Install camshaft sprockets and timing chain.
  • Tighten camshaft sprocket bolts. Tightening torque:
    • • Inlet camshaft sprocket – 40 Nm + 90°.
      • Exhaust camshaft sprocket – 50 Nm + 90°.
      • Tighten crankshaft pulley bolt to 150 Nm + 180°.

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

  • Remove camshaft alignment tool. Turn crankshaft two turns clockwise.
  • Check valve timing [3] .