How to Replace timing belt on Audi A3 8P MK2 2.0 TDI 2005-2008 BMM

Replacement Interval Guide

• Audi recommend replacement every 75,000 miles or 5 years (tensioner pulley must also be replaced).
• 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

2,20

Special Tools

• Auxiliary drive belt tensioner locking pin – Audi No.T10060A.
• Camshaft sprocket holding tool – Audi No.T10172/4.
• Camshaft sprocket locking tool – Audi No.3359.
• Crankshaft sprocket locking tool – Audi No.T10050 or T10100.
• Tensioner pulley locking pin – Audi No.T10265.
• Tensioning tool – Audi No.T10264.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow 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 top cover.
   • RH front wheel.
   • Engine undershield.
   • RH wheel arch liner.
3. Disconnect:
   • Fuel supply and return pipes.
   • Coolant expansion tank hose.
4. Remove:
   • Turbocharger inlet hose.
   • Throttle body assembly.
   • Fuel filter. DO NOT disconnect pipes.
   • Fuel filter bracket.
   • Windscreen washer reservoir filler neck.
   • Coolant expansion tank. DO NOT disconnect hoses.
   • Auxiliary drive belt. Use tool No.T10060A.

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

   • Auxiliary drive belt tensioner.
   • Timing belt upper cover [1] .
   • Turbocharger lower air duct.
   • Crankshaft pulley centre cap.
   • Crankshaft pulley bolts [2] .
   • Crankshaft pulley [3] .
   • Timing belt centre cover [4] .
   • Timing belt lower cover [5] .
5. Turn crankshaft clockwise to TDC on No.1 cylinder.
6. Ensure camshaft sprocket window at position as shown [6] .
7. Ensure timing mark aligned with notch on camshaft sprocket hub [7] .

   NOTE: Notch located behind camshaft sprocket teeth.

8. Lock camshaft. Use tool No.3359 [8] .
9. Lock crankshaft sprocket:
   • Type A: Use tool No.T10050 [A] .
   • Type B: Use tool No.T10100 [B] .

   NOTE: Ensure lug of crankshaft sprocket locking tool located in oil seal housing [9] .

10. Ensure timing marks aligned [10] .
11. Slacken camshaft sprocket bolts [11] .

    NOTE: Slacken bolts until sprocket can be moved within slotted holes.

12. Slacken tensioner pulley nut [12] .
13. Turn tensioner pulley anti-clockwise until locking pin can be inserted [13] . Use tool No.T10264 [14] .
14. Insert locking pin in tensioner pulley [15] . Tool No.T10265.
15. Turn tensioner pulley fully clockwise until it reaches stop [16] . Use tool No.T10264 [14] .
16. Lightly tighten tensioner pulley nut [12] .
17. Remove timing belt, starting at water pump sprocket.

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

Installation

NOTE: Engine must be cold.

1. Ensure camshaft locked with tool [8] .
2. Ensure crankshaft sprocket locking tool located correctly [A] or [B] .

   NOTE: Ensure lug of crankshaft sprocket locking tool located in oil seal housing [9] .

3. Ensure timing marks aligned [10] .
4. Ensure tensioner pulley locking pin inserted [15] .
5. Ensure tensioner pulley retaining lug is properly engaged [17] .
6. Turn camshaft sprocket fully clockwise in slotted holes.

   NOTE: Sprocket should turn freely without tilting.

7. Fit timing belt in following order:
   • Camshaft sprocket.
   • Tensioner pulley.
   • Crankshaft sprocket.
   • Water pump sprocket.

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

8. Remove locking pin from tensioner pulley [15] .
9. Slacken tensioner pulley nut [12] .
10. Turn tensioner pulley slowly clockwise until pointer aligned with notch [18] .

    NOTE: Ensure tensioner pulley nut does not turn [12] .

11. Hold tensioner pulley. Use tool No.T10264 [14] .
12. Tighten tensioner pulley nut [12] . Tightening torque: 20 Nm + 45°.

    NOTE: As tensioner pulley nut is tightened, the pointer may move clockwise 5 mm maximum. DO NOT adjust position of tensioner pulley. Timing belt will settle once run in.

13. Hold camshaft sprocket. Use tool No.T10172/4.

    NOTE: Ensure belt is taut between sprockets on non-tensioned side.

14. Tighten camshaft sprocket bolts [11] . Tightening torque: 25 Nm.
15. Remove:
    • Camshaft sprocket holding tool.
    • Camshaft sprocket locking tool [8] .
    • Crankshaft sprocket locking tool [A] or [B] .
16. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
17. Fit camshaft sprocket locking tool while slowly turning crankshaft to TDC [8] .
18. Ensure timing mark aligned with notch on camshaft sprocket hub [7] .

    NOTE: Notch located behind camshaft sprocket teeth.

19. Ensure crankshaft sprocket locking tool can be inserted easily [A] or [B] .

    NOTE: Ensure lug of crankshaft sprocket locking tool located in oil seal housing [9] .

20. Ensure timing marks aligned [10] .
21. Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch [18] .
22. If crankshaft sprocket locking tool cannot be inserted [A] or [B] :
    • Hold camshaft sprocket. Use tool No.T10172/4.
    • Slacken camshaft sprocket bolts [11] .

      NOTE: Slacken bolts until sprocket can be moved within slotted holes.

    • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [9] .
    • Turn crankshaft clockwise until lug and hole aligned [9] .
    • Lock crankshaft sprocket [A] or [B] .

      NOTE: Ensure lug of crankshaft sprocket locking tool located in oil seal housing [9] .

    • Ensure timing marks aligned [10] .
    • Hold camshaft sprocket. Use tool No.T10172/4.

      NOTE: Ensure belt is taut between sprockets on non-tensioned side.

    • Tighten camshaft sprocket bolts [11] . Tightening torque: 25 Nm.
    • Remove camshaft sprocket locking tool [8] .
    • Remove crankshaft sprocket locking tool [A] or [B] .
    • Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
    • Fit camshaft sprocket locking tool while slowly turning crankshaft to TDC [8] .
    • Ensure crankshaft sprocket locking tool can be inserted easily [A] or [B] .

      NOTE: Ensure lug of crankshaft sprocket locking tool located in oil seal housing [9] .

    • Ensure timing marks aligned [10] .
    • Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch [18] .
    • Remove camshaft sprocket locking tool [8] .
    • Remove crankshaft sprocket locking tool [A] or [B] .
23. Install components in reverse order of removal.
24. Tighten crankshaft pulley bolts [2] . Tightening torque: 10 Nm + 90°. Use new bolts.