How to Replace timing belt on Audi A3 8P MK2 1.6 2005-2012

Аudi А3 Cambelt Change Interval

• →2003MY: No manufacturer’s recommended replacement interval.NOTE: Audi UK recommend the timing belt is replaced every 5 years.
• 2004MY→: Audi recommend replacement every 75,000 miles or 5 years.
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

• CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur.

• A compression check of all cylinders should be performed before removing the cylinder head(s).

Repair Times – hrs

Special Tools

• Engine support – No.10-222A.
• Two-pin wrench – No.T10020.

Special Precautions

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

• Removal

  1. Raise and support front of vehicle.
  2. Remove:
     • • Engine undershield.
       • RH front wheel.
       • RH front inner wing panel.
       • Engine upper cover.
  3. Disconnect:
     • • Vacuum pipe to evaporative emission (EVAP) canister.
       • Fuel supply pipe.
  4. Move evaporative emission (EVAP) canister to one side.
  5. Remove:
     • • Evaporative emission (EVAP) canister bracket.
       • Windscreen washer reservoir filler neck.
  6. Disconnect coolant expansion tank multi-plug.
  7. Remove:
     • • Coolant expansion tank. DO NOT disconnect hoses.
       • Auxiliary drive belt splash shield.
       • Auxiliary drive belt. Lock tensioner in position. Use Allen key.
       • Auxiliary drive belt tensioner.
       • Timing belt upper cover [1] .
  8. Turn crankshaft to TDC on No.1 cylinder.
  9. Ensure crankshaft pulley timing marks aligned [2] .
  10. Ensure camshaft sprocket timing marks aligned [3] .
  11. Remove:
      • • Crankshaft pulley bolts [4] .
        • Crankshaft pulley [5] .
        • Timing belt centre cover [6] .
        • Timing belt lower cover [7] .
  12. Install engine support. Tool No.10-222A.
  13. Remove:
      • • RH engine mounting bolts [8] , [9] & [10] .
        • RH engine mounting.
        • RH engine mounting bracket bolts [11] .
        • RH engine mounting bracket [12] .

      NOTE: Engine may need to be raised/lowered slightly.

  14. Slacken tensioner nut [13] . Turn tensioner clockwise away from belt. Use tool No.T10020 [14] . Lightly tighten nut [13] .
  15. Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

  Installation

  1. Ensure camshaft sprocket timing marks aligned [3] .
  2. Fit timing belt to crankshaft sprocket and water pump sprocket.
  3. Install:
     • • Timing belt lower cover [7] .
       • Timing belt centre cover [6] .
       • Crankshaft pulley [5] .
       • Crankshaft pulley bolts [4] .
  4. Tighten crankshaft pulley bolts [4] . Tightening torque: 10 Nm + 90°. Use new bolts.
  5. Ensure crankshaft pulley timing marks aligned [2] .
  6. Fit timing belt to tensioner pulley and camshaft sprocket.NOTE: Ensure belt is taut between sprockets on non-tensioned side.
  7. Ensure tensioner retaining lug is properly engaged [15] .
  8. Slacken tensioner nut [13] .
  9. Turn tensioner twice fully anti-clockwise and clockwise from stop to stop. Use tool No.T10020 [14] .
  10. Turn tensioner anti-clockwise until pointer [16] aligned with notch [17] in baseplate. Use tool No.T10020 [14] .
  11. Tighten tensioner nut [13] . Tightening torque: 23 Nm.
  12. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.NOTE: Turn crankshaft last 45° smoothly without stopping.
  13. Ensure camshaft sprocket timing marks aligned [3] .
  14. Ensure crankshaft pulley timing marks aligned [2] .
  15. Ensure pointer [16] aligned with notch [17] in baseplate.
  16. If not: Repeat tensioning procedure.
  17. Apply firm thumb pressure to belt at . Pointer [16] and notch [17] must move apart.
  18. Release thumb pressure from belt at .
  19. Turn crankshaft two turns clockwise to TDC on No.1 cylinder.NOTE: Turn crankshaft last 45° smoothly without stopping.
  20. Ensure camshaft sprocket timing marks aligned [3] .
  21. Ensure crankshaft pulley timing marks aligned [2] .
  22. Ensure pointer [16] aligned with notch [17] in baseplate.
  23. Install:
      • • RH engine mounting bracket [12] .
        • RH engine mounting bracket bolts [11] .
  24. Tighten RH engine mounting bracket bolts [11] . Tightening torque: 45 Nm.
  25. Fit and align RH engine mounting:
      • • Engine mounting clearance: 16 mm [18] .
        • Ensure engine mounting aligned parallel with engine mounting bracket [19] .
  26. Tighten:
      • • Engine mounting bolts [9] . Tightening torque: 40 Nm + 90°. Use new bolts.
        • Engine mounting bolts [8] . Tightening torque: 20 Nm + 90°. Use new bolts.
        • Engine mounting bolts [10] . Tightening torque: 60 Nm + 90°. Use new bolts.
  27. Install components in reverse order of removal.NOTE: The manufacturer recommends bleeding the fuel system before starting engine.