How to Replace timing chain on Audi A3 8P MK2 2.0 FSI 2005-2008

A3 Audi

Special tools

  • Camshaft alignment tool – No.T10252.
  • Camshaft adjuster socket – No.40080.
  • Chain tensioner retaining tool – No.T10092.
  • Chain tensioner locking pin – No.T10115.
  • Two-pin wrench – No.T10020.

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.
How to Replace timing chain on Audi A3 2.0 FSI 2005-2008

Valve timing procedures

  • Engine at TDC on No.1 cylinder [1] .
  • Ensure timing mark on timing belt camshaft sprocket aligned with mark on timing belt rear cover [2] .
  • Ensure indents on camshafts positioned as shown [3] .
  • Install camshaft alignment tool [4] .
  • Slacken exhaust camshaft adjuster bolt.

NOTE: There are two types of tensioner.

  • Tensioner – type A:
      • Compress timing chain tensioner and lock with retaining tool and M5 nut [5] .
      • Remove timing chain tensioner bolt [6] .

NOTE: DO NOT overtighten chain tensioner retaining tool as damage may occur.

  • Tensioner – type B:
      • Compress timing chain tensioner and lock with locking pin [7] .
  • Remove exhaust camshaft adjuster and chain.
  • Ensure engine at TDC on No.1 cylinder [1] .
  • Ensure camshaft alignment tool correctly located [4] .
  • Fit camshaft adjuster and chain. Use new bolt.
  • Ensure exhaust camshaft adjuster locating pin aligned with notch on camshaft [8] [9] .
  • If not, repeat installation procedures.
  • Tighten bolt of exhaust camshaft adjuster. Tightening torque: 20 Nm + 45°.
  • Release tensioner after timing chain installation:
  • Tensioner – type A:
      • Install timing chain tensioner bolt [6] . Tightening torque: 10 Nm.
      • Remove chain tensioner retaining tool and M5 nut [5] .
  • Tensioner – type B:
      • Remove locking pin [7] .
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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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