Replacement Interval Guide
- Audi recommend:
- →2003MY: Replacement every 115,000 miles.NOTE: Audi UK recommend the timing belt is replaced every 5 years.
- 2004MY→: 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
Remove & install: | |
---|---|
A3 | 2,50 |
S3 | 2,90 |
TT | 3,70 |
Special Tools
- Auxiliary drive belt tensioner locking pin – Audi No.T10060A.
- Two-pin wrench – Audi No.T10020.
- Auxiliary drive belt tensioner tool – Audi No.U40050.
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
- Raise and support front of vehicle.
- Remove:
- Engine undershield.
- RH front wheel.
- RH front inner wing panel.
- Engine top cover.
- S3: Turbocharger lower air duct.
- S3: Engine lower tie-bar.
- Drain cooling system.
- Disconnect:
- Fuel vapour hose from evaporative emission (EVAP) canister.
- Fuel supply and return pipes.
- Move evaporative emission (EVAP) canister to one side.
- Remove:
- Evaporative emission (EVAP) canister bracket.
- Windscreen washer reservoir filler neck.
- Disconnect coolant expansion tank multi-plug.
- Disconnect coolant hose from timing belt upper cover.
- TT: Unclip coolant expansion tank lower hose.
- Remove:
- Coolant expansion tank. DO NOT disconnect hoses.
- With AC: Auxiliary drive belt. Use tool No.T10060A.
- With AC: Auxiliary drive belt tensioner.
- Without AC: Auxiliary drive belt. Use tool No.U40050.
NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
- Support engine.NOTE: Remove auxiliary drive belt tensioner locking pin No.T10060A before removing RH engine mounting.
- Remove:
- RH engine mounting [1] .
- RH engine mounting bracket bolts [2] .
- RH engine mounting bracket [3] .
NOTE: Engine may need to be raised/lowered slightly.
- Remove timing belt upper cover inspection plate [4] .
- Turn crankshaft clockwise to TDC on No.1 cylinder.
- Ensure timing marks aligned [5] & [6] .
- Remove:
- Crankshaft pulley bolts [7] .
- Crankshaft pulley [8] .
- Timing belt upper cover [9] .
- Timing belt lower cover [10] .
- Slacken tensioner pulley nut [11] .
- Turn tensioner pulley clockwise away from belt. Use tool No.T10020 [12] or Allen key. Lightly tighten nut [11] .
- Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
Installation
NOTE: Engine must be COLD.
- Check tensioner pulley and guide pulleys for smooth operation. Replace if necessary.
- Ensure camshaft sprocket timing marks aligned [6] .
- Fit timing belt to crankshaft sprocket.NOTE: If reusing old belt, observe direction of rotation marks on belt.
- Install:
- Timing belt lower cover [10] .
- Crankshaft pulley [8] .
- Crankshaft pulley bolts [7] . Use new bolts.
- Tighten crankshaft pulley bolts [7] . Tightening torque: 10 Nm + 90°.
- Ensure crankshaft pulley timing marks aligned [5] .
- Fit timing belt in following order:
- Guide pulley (G1).
- Tensioner pulley.
- Camshaft sprocket.
- Water pump sprocket.
- Guide pulley (G2).
NOTE: Ensure belt is taut between sprockets on non-tensioned side.
- Ensure retaining lug located in slot in cylinder head [13] .
- Slacken tensioner pulley nut [11] .
- Turn tensioner pulley clockwise until notch [14] is above lug [15] in baseplate. Use tool No.T10020 [12] or Allen key.
- Turn tensioner pulley anti-clockwise to release tension on belt. Use tool No.T10020 [12] or Allen key.
- Turn tensioner pulley clockwise until notch aligned with lug in baseplate [15] & [16] . Use tool No.T10020 [12] or Allen key.
- Tighten tensioner pulley nut [11] . Tightening torque: 25 Nm.
- Turn crankshaft slowly two turns clockwise until timing marks aligned [5] & [6] .NOTE: Turn crankshaft last 45° smoothly without stopping.
- Ensure notch aligned with lug in baseplate [16] & [15] .
- If not: Repeat tensioning procedure.
- Install:
- Timing belt upper cover [9] .
- RH engine mounting bracket [3] .
- RH engine mounting bracket bolts [2] .
- Tighten RH engine mounting bracket bolts [2] . Tightening torque: 40 Nm.
- Lower engine slightly.
- Fit and align RH engine mounting [1] :
- Engine mounting clearance: 16 mm [17] .
- Ensure engine mounting aligned parallel with engine mounting bracket [18] .
- Tighten:
- Engine mounting bolts [19] . Tightening torque: 40 Nm + 90°. Use new bolts.
- Engine mounting bolts [20] . Tightening torque: 20 Nm + 90°. Use new bolts.
- Engine mounting bolts [21] . Tightening torque: 60 Nm + 90°. Use new bolts.
- Install components in reverse order of removal.
- Refill cooling system.NOTE: The manufacturer recommends bleeding the fuel system before starting engine.
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