How to Replace timing gears on Audi A3 8P MK2 1.6 TDI 2009

A3 Audi

Special tools

  • Camshaft alignment tool – No.T40094.
  • Camshaft holding tool – No.T40095.
  • Camshaft sprocket hub holding tool – No.T10051.
  • Camshaft sprocket hub puller – No.T10052.
  • Camshaft/high-pressure fuel pump locking tool – No.3359.
  • Crankshaft sprocket locking tool – No.T10050.
  • Two-piece exhaust camshaft gear alignment tool – No.T40096/1.

General precautions

  • Disconnect battery earth lead.
  • Remove glow 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 gears.
  • Do NOT turn crankshaft or camshaft with timing gear(s) removed.
How to Replace timing gears on Audi A3 1.6 TDI 2009-

Valve timing procedures

  • Removal/installation of timing gears requires:
      • Timing belt removal.
      • Removal of camshafts.
  • Engine at TDC on No.1 cylinder.
  • Fit crankshaft sprocket locking tool [1] .
  • Ensure timing marks aligned [2] .
  • Install camshaft sprocket locking tool [3] .
  • Fit inlet camshaft on camshaft alignment tool [4] .
  • Ensure camshaft alignment tool engages in end of camshaft [5] .
  • Fit exhaust camshaft on camshaft alignment tool [6] .
  • Ensure camshaft alignment tool engages in end of camshaft [7] .
  • Ensure indents on camshafts are facing outwards [8] .
  • If fitted: Align gear teeth of two-piece exhaust camshaft gear with camshaft gear alignment tool [9] .
  • Move inlet camshaft in direction of arrow to engage teeth of camshaft gears [10] .
  • Fit camshaft housing on camshafts [11] .
  • Retain camshafts in position with camshaft holding tool [12] .
  • Disengage camshaft alignment tool from end of camshafts [5] [7] .
  • Remove camshaft housing and camshafts held in position with special tools from camshaft alignment tool.
  • Place camshaft housing with camshafts and special tools on cylinder head [11] .
  • Ensure crankshaft sprocket locking tool located correctly [1] .
  • Ensure timing marks aligned [2] .
  • Refit camshaft housing [11] .
  • Remove special tools [9] [12] .

NOTE: Allow 30 minutes after installing camshafts before starting engine to prevent engine damage.

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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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