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

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.

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