How to Replace timing chain on Audi A5 (8T) 2.0 TFSI 2009

A5 Audi

Audi A5 (8T) 2.0 TFSI 2009 timing chain change instructions and replacement interval. Full guide!

Special tools

  • Camshaft adjuster control valve removal tool – No.T10352.
  • Camshaft adjuster control valve removal tool – No.T10352/1.
  • Crankshaft pulley holding tool – No.T10355.
  • Dial gauge – No.VAS 6079.
  • Dial gauge adapter – No.T10170A/1.
  • Tensioner locking pin – No.T40011.
  • Tensioner locking tool – No.T40267.

Special 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

  • Engine at TDC on No.1 cylinder.
  • Install dial gauge and adapter in No.1 cylinder plug hole [1] .
  • Turn crankshaft slowly to TDC on No.1 cylinder. Use dial gauge [1] .
  • Ensure crankshaft pulley timing mark aligned with timing mark on chain cover [2] .

WARNING: Crankshaft sprocket not keyed to crankshaft. Ensure crankshaft sprocket timing marks aligned [3]<1>.

  • Refit crankshaft pulley bolt with spacer.
  • Remove inlet camshaft adjuster control valve (LH thread) [5] .
  • Remove exhaust camshaft sprocket bolt and washer [4] .
  • Remove camshaft support bracket [6] .
  • Ensure camshaft sprocket timing marks aligned [7] .
  • Ensure coloured or painted chain links aligned with timing mark on each camshaft sprocket [7] .
  • Ensure balancer shaft timing marks aligned [8] .
  • Ensure balancer shaft gear timing marks aligned [9] .
  • Ensure crankshaft sprocket timing marks aligned [10] & [11] .
  • Reset tensioner:
  • Type A [12] :
    • Release locking mechanism using a suitable tool [13] .
    • Push plunger into tensioner housing [14] .
    • Insert tensioner locking pin [15] .
  • Type B [16] :
    • Release tensioner plunger retaining clip [17] .
    • Push plunger into tensioner housing [18] .
    • Insert tensioner locking tool [19] .
  • Remove tensioner locking tool or pin to release timing chain tensioner plunger [15] or [19] .
  • Tighten exhaust camshaft sprocket bolt [4] .
  • Turn crankshaft two turns clockwise.
  • Ensure engine at TDC on No.1 cylinder. Use dial gauge [1] .
  • Ensure timing mark on each camshaft sprocket positioned as shown [7] .
  • Check measurement between outer edge of raised cast section on upper chain guide and timing mark on inlet camshaft adjuster is 61-64 mm [20] & [21] .

NOTE: If measurement outside tolerance, repeat timing chain installation procedure.

  • Check measurement between inlet camshaft adjuster timing mark and exhaust camshaft sprocket timing mark is 124-126 mm [22] .

NOTE: If measurement outside tolerance, repeat timing chain installation procedure.

How to Replace timing chain on Audi A5 (8T) 2.0 TFSI 2009
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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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