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How to Replace timing chain on Audi A3 8P MK2 1.6 FSI 2005-2007

Special tools

  • Camshaft alignment tool – Tool No.T10171.
  • Dial gauge – Tool No.VAS 6079.
  • Dial gauge holder – Tool No.T10170.
  • Tensioner locking tool – Tool No.T40011.
  • Crankshaft pulley/camshaft sprocket holding tool – Tool No.T10172.

General 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

    • Removal/installation of timing chain requires:
        • Timing chain cover removal.
        • Sump removal.
    • Install dial gauge and holder in No.1 cylinder plug hole. Ensure engine at TDC on No.1 cylinder [1] .
    • Ensure timing marks on camshafts aligned as shown. If not, turn crankshaft 360° [2] .
    • Fit camshaft alignment tool [3] .

      NOTE: If camshaft alignment tool cannot be inserted valve timing is incorrect.

    • Fit tensioner locking tool [4] .
    • Remove camshaft sprockets and chain.NOTE: Inlet camshaft sprocket bolt has LH thread.
    • Align camshafts. Use special tool [3] .
    • Install camshaft sprockets and timing chain.
    • Tighten camshaft sprocket bolts. Tightening torque:
        • Inlet camshaft sprocket – 40 Nm + 90°.
        • Exhaust camshaft sprocket – 50 Nm + 90°.
        • Tighten crankshaft pulley bolt to 150 Nm + 180°.

    NOTE: Crankshaft pulley bolt and bolt on each camshaft sprocket MUST only be used once.

    • Remove camshaft alignment tool. Turn crankshaft two turns clockwise.
    • Check valve timing [3] .

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