How to Replace timing chain on Audi TT 2.0 TDi 2009

Audi TT

Special tools

  • Auxiliary drive belt tensioner locking pin – No.T10060A.
  • Camshaft sprocket/high-pressure fuel pump sprocket holding tool – Nos.T10172/4.
  • Camshaft sprocket/high-pressure fuel pump sprocket locking tool – No.3359 (x 2).
  • Crankshaft sprocket locking tool – No.T10050.
  • Multi-spline socket – No.T10385.
  • Tensioner pulley adjusting tool – No.T10264.
  • Tensioner pulley locking tool – No.T10265.

Special precautions

  • Disconnect battery earth lead.
  • DO NOT turn crankshaft or camshaft when timing belt removed.
  • Remove glow 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.

Repair times – hrs

Camshaft drive belt/chain – R & I2,20

Valve timing procedures

How to Replace timing belt on Audio TT 2.0 DTi 2009

Removal

  1. Raise and support front of vehicle.
  2. Remove:
    • Engine upper cover.
    • RH front wheel.
    • Engine undershield.
    • RH splash guard.
    • A3 Cabrio/TT: Engine undershield mounting bracket.
  3. Disconnect diesel particulate filter (DPF) pressure sensor multi-plug.
  4. Reposition:
    • A1/A3: Diesel particulate filter (DPF) pressure sensor bracket.
    • A3: Windscreen washer reservoir filler neck.
  5. A3/Q3/TT: Unclip fuel hose from fuel hose support bracket.
  6. A3/Q3/TT: Reposition fuel hose support bracket.
  7. A3/Q3/TT: Disconnect fuel lift pump multi-plug.
  8. A3/Q3/TT: Reposition fuel lift pump support bracket.
  9. A3/Q3/TT: Reposition fuel filter. DO NOT disconnect fuel pipes.
  10. Disconnect engine coolant temperature (ECT) sensor multi-plug.
  11. A1: Move coolant expansion tank to one side. DO NOT disconnect hoses.
  12. A3/Q3/TT: Reposition coolant hose from timing belt upper cover. DO NOT disconnect hose.
  13. Support engine.
  14. Remove:
    • RH engine mounting and bracket.
    • Timing belt upper cover [1] .
    • Auxiliary drive belt. Use tool No.T10060A.

    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

    • Crankshaft pulley bolts [2] .
    • Crankshaft pulley [3] .
    • Timing belt centre cover [4] .
    • Timing belt lower cover [5] .
  15. Turn crankshaft clockwise to TDC on No.1 cylinder.
  16. Camshaft sprocket – type A: Ensure camshaft sprocket window at approximately 12 o’clock position [6] . If not: Turn crankshaft one turn clockwise.
  17. Camshaft sprocket – type B: Ensure camshaft sprocket timing hole at 7 o’clock position [7] . If not: Turn crankshaft one turn clockwise.
  18. Lock camshaft sprocket [7] . Use tool No.3359.
  19. Lock crankshaft sprocket [8] . Use tool No.T10050.
  20. Ensure timing marks aligned [9] .
  21. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [10] .
  22. Slacken camshaft sprocket bolts [11] .
  23. Slacken high-pressure fuel pump sprocket bolts [12] . Use tool No.T10385.
    NOTE: Sprockets should turn freely but not tilt.
  24. Slacken tensioner pulley nut [13] .
  25. Turn tensioner pulley anti-clockwise until locking tool can be inserted [14] . Use tool No.T10264 [15] .
  26. Insert locking tool in tensioner pulley [16] . Tool No.T10265.
  27. Turn tensioner pulley fully clockwise until it reaches stop [17] . Use tool No.T10264 [15] .
  28. Tighten tensioner pulley nut finger tight [13] .
  29. Remove timing belt, starting at guide pulley (G3).
    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: Engine must be COLD.

  1. Fit new high-pressure fuel pump sprocket bolts [12] . Tighten bolts finger tight.
  2. Ensure tensioner pulley locking tool inserted [16] .
  3. Ensure camshaft sprocket locking tool located correctly [7] .
  4. Ensure crankshaft sprocket locking tool located correctly [10] .
  5. Ensure timing marks aligned [9] .
  6. Lock high-pressure fuel pump sprocket [18] . Use tool No.3359.
  7. If locking tool cannot be inserted [18] : Turn high-pressure fuel pump sprocket as required.
  8. Turn camshaft sprocket and high-pressure fuel pump sprocket fully clockwise in slotted holes.
  9. Fit timing belt in following order:
    • Crankshaft sprocket.
    • Guide pulley (G1).
    • Tensioner pulley.
    • Camshaft sprocket.
    • Water pump sprocket.
    • Guide pulley (G3).
    • High-pressure fuel pump sprocket.
    • Guide pulley (G2).
  10. Slacken tensioner pulley nut [13] .
  11. Remove locking tool from tensioner pulley [16] .
  12. Ensure tensioner pulley retaining lug is properly engaged [19] .
  13. Turn camshaft sprocket anti-clockwise to remove slack from belt between camshaft sprocket and high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
  14. Hold camshaft sprocket. Use tool Nos.T10172/4.
  15. Tighten camshaft sprocket and high-pressure fuel pump sprocket bolts [11] & [12] . Tightening torque: 20 Nm.
  16. Turn tensioner pulley slowly clockwise until pointer aligned with notch [20] .
    NOTE: Ensure tensioner pulley nut does not turn [13] .
  17. Hold tensioner pulley. Use tool No.T10264 [15] .
  18. Tighten tensioner pulley nut [13] . Tightening torque: 20 Nm + 45°.
  19. Remove:
    • Camshaft sprocket locking tool [7] .
    • High-pressure fuel pump sprocket locking tool [18] .
    • Crankshaft sprocket locking tool [8] .
  20. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
  21. Fit crankshaft sprocket locking tool while slowly turning crankshaft to TDC [8] .
  22. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [10] .
  23. Ensure timing marks aligned [9] .
  24. Ensure camshaft sprocket locking tool can be inserted easily [7] .
    NOTE: DO NOT insert high-pressure fuel pump sprocket locking tool as alignment hole may be slightly misaligned. No adjustment required.
  25. Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch [20] . If not: Repeat installation procedure.
  26. If camshaft sprocket locking tool cannot be inserted easily [7] :
    • Remove lug of crankshaft sprocket locking tool from hole in oil seal housing.
    • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [21] .
    • Turn crankshaft clockwise until camshaft locking tool can be inserted [7] .
    • Slacken camshaft sprocket bolts [11] .

    NOTE: Lug of crankshaft sprocket locking tool will be positioned to the left or right of hole in oil seal housing.

  27. If lug of crankshaft sprocket locking tool is positioned to the left of hole in oil seal housing:
    • Turn crankshaft clockwise until lug and hole aligned [10] .
    • Lock crankshaft sprocket [8] .
    • Ensure timing marks aligned [9] .
    • Hold camshaft sprocket. Use tool Nos.T10172/4.
    • Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.
  28. If lug of crankshaft sprocket locking tool is positioned to the right of hole in oil seal housing:
    • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [21] .
    • Turn crankshaft clockwise until lug and hole aligned [10] .
    • Lock crankshaft sprocket [8] .
    • Ensure timing marks aligned [9] .
    • Hold camshaft sprocket. Use tool Nos.T10172/4.
    • Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.
  29. Remove:
    • Camshaft sprocket locking tool [7] .
    • Crankshaft sprocket locking tool [8] .
  30. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
  31. Ensure locking tools can be inserted [8] & [7] .
  32. Ensure timing marks aligned [9] .
  33. Hold camshaft sprocket. Use tool Nos.T10172/4.
  34. Tighten camshaft sprocket bolts [11] . Tightening torque: 25 Nm.
  35. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
  36. Ensure locking tools can be inserted [8] & [7] .
  37. Ensure timing marks aligned [9] .
  38. Remove locking tools [8] & [7] .
  39. Install components in reverse order of removal.
  40. Tighten crankshaft pulley bolts [2] . Tightening torque: 10 Nm + 90°. Use new bolts.
0 0 vote
Article Rating
Bent Valves
Timing Tools?
Misconception
Need More?
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.  

Need More?
Subscribe
Notify of
guest
0 Comments
Inline Feedbacks
View all comments
0
Would love your thoughts, please comment.x
()
x