How to Replace timing belt on Audi S3 2.0 TFSI 2008

Audi S3 2.0 TFSI 2008 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Auxiliary drive belt tensioner locking pin – Audi No.T10060A.

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.

Repair times – hrs

Camshaft drive belt/chain – R & I

2,90

Valve timing procedures

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Engine undershield.
   • RH front wheel.
   • RH front inner wing panel.
   • Engine top cover.
   • S3: Engine lower torque reaction link.
3. Drain cooling system.
4. Disconnect fuel vapour hose from evaporative emission (EVAP) canister.
5. Move evaporative emission (EVAP) canister to one side.
6. Remove evaporative emission (EVAP) canister bracket.
7. Disconnect coolant expansion tank multi-plugs.
8. Disconnect coolant hose from timing belt upper cover.
9. Unclip coolant expansion tank lower hose.
10. Remove:
    • S3: Windscreen washer reservoir filler neck.
    • Coolant expansion tank.
    • Auxiliary drive belt. Use tool No.T10060A.
    • Auxiliary drive belt tensioner.

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

11. Support engine.
12. Remove:
    • RH engine mounting [1] .
    • RH engine mounting bracket bolts [2] .
    • RH engine mounting bracket [3] .
    • S3: Turbocharger to intercooler pipe.

    NOTE: Engine may need to be raised/lowered slightly

13. Remove timing belt upper cover [4] .
14. Turn crankshaft clockwise to TDC on No.1 cylinder.
15. Ensure timing marks aligned [5] & [6] .
16. Remove:
    • Crankshaft pulley bolts [7] .
    • Crankshaft pulley [8] .
    • Timing belt lower cover [9] .
17. Mark crankshaft sprocket and cylinder block with paint or chalk [10] .
18. Slacken tensioner pulley nut [11] .
19. Turn tensioner pulley clockwise away from belt. Use Allen key [12] . Lightly tighten nut [11] .
20. Remove timing belt.
    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: Engine must be COLD.

1. Check tensioner pulley and guide pulleys for smooth operation. Replace if necessary.
2. Ensure camshaft sprocket timing marks aligned [5] .
3. Ensure crankshaft sprocket timing marks aligned [10] .
4. Fit timing belt in following order:
   • Crankshaft sprocket.
   • Guide pulley (G1).
   • Tensioner pulley.
   • Camshaft sprocket.
   • Water pump sprocket.
   • Guide pulley (G2).

   NOTE: If reusing old belt, observe direction of rotation marks on belt. Ensure belt is taut between sprockets on non-tensioned side.

5. Ensure retaining lug located in slot in cylinder head [13] .
6. Slacken tensioner pulley nut [11] .
7. Turn tensioner pulley clockwise until notch [14] is above lug [15] in baseplate. Use Allen key [12] .
8. Turn tensioner pulley anti-clockwise to release tension on belt.
9. Turn tensioner pulley clockwise until notch aligned with lug in baseplate [15] & [16] . Use Allen key [12] .
10. Tighten tensioner pulley nut [11] . Tightening torque: 25 Nm.
11. Turn crankshaft slowly two turns clockwise until timing marks aligned [5] & [10] .
    NOTE: Turn crankshaft last 45° smoothly without stopping.
12. Ensure notch aligned with lug in baseplate [15] & [16] .
13. If not:
    • Slacken tensioner pulley nut [11] .
    • Turn tensioner pulley clockwise until notch aligned with lug in baseplate [15] & [16] . Use Allen key [12] .
    • Tighten tensioner pulley nut [11] . Tightening torque: 25 Nm.
14. Ensure timing marks aligned [5] & [10] .
15. If not: Repeat tensioning procedure.
16. Install:
    • Timing belt upper cover [4] .
    • RH engine mounting bracket [3] .
    • RH engine mounting bracket bolts [2] .
17. Tighten RH engine mounting bracket bolts [2] . Tightening torque: 45 Nm.
18. Lower engine slightly.
19. Fit and align RH engine mounting:
    • Engine mounting clearance: 16 mm [17] .
    • Ensure engine mounting aligned parallel with engine mounting bracket [18] .
20. 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.
21. Install:
    • Timing belt lower cover [9] .
    • Crankshaft pulley [8] .
22. Fit new crankshaft pulley bolts [7] . Tightening torque:
    • A – TT: 10 Nm + 90°.
    • B – S3: 20 Nm + 90°.
23. Ensure timing marks aligned [5] & [6] .
24. Install components in reverse order of removal.
25. Refill cooling system.