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How to Replace timing chain on Audi TT 2.0 TFSI 2009

Audi TT 2.0 TFSI 2009 cambelt change instructions and replacement inteval. Full guide!

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.

Valve timing procedures

How to Replace timing belt on Audi TT 2.0 TFSI 2009
How to Replace timing belt on Audi TT 2.0 TFSI 2009

Removal

  1. Raise and support front of vehicle.
  2. Remove:
    • Engine undershield.
    • RH front wheel.
    • RH front inner wing panel.
    • Engine top cover.
    • S3: Turbocharger lower air duct.
    • S3: Engine lower tie-bar.
  3. Drain cooling system.
  4. Disconnect:
    • Fuel vapour hose from evaporative emission (EVAP) canister.
    • Fuel supply and return pipes.
  5. Move evaporative emission (EVAP) canister to one side.
  6. Remove:
    • Evaporative emission (EVAP) canister bracket.
    • Windscreen washer reservoir filler neck.
  7. Disconnect coolant expansion tank multi-plug.
  8. Disconnect coolant hose from timing belt upper cover.
  9. TT: Unclip coolant expansion tank lower hose.
  10. 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.

  11. Support engine.
    NOTE: Remove auxiliary drive belt tensioner locking pin No.T10060A before removing RH engine mounting.
  12. 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.
  13. Remove timing belt upper cover inspection plate [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 upper cover [9] .
    • Timing belt lower cover [10] .
  17. Slacken tensioner pulley nut [11] .
  18. Turn tensioner pulley clockwise away from belt. Use tool No.T10020 [12] or Allen key. Lightly tighten nut [11]
  19. 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 [6] .
  3. Fit timing belt to crankshaft sprocket.
    NOTE: If reusing old belt, observe direction of rotation marks on belt.
  4. Install:
    • Timing belt lower cover [10] .
    • Crankshaft pulley [8] .
    • Crankshaft pulley bolts [7] . Use new bolts.
  5. Tighten crankshaft pulley bolts [7] . Tightening torque: 10 Nm + 90°.
  6. Ensure crankshaft pulley timing marks aligned [5] .
  7. 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.

  8. Ensure retaining lug located in slot in cylinder head [13] .
  9. Slacken tensioner pulley nut [11] .
  10. Turn tensioner pulley clockwise until notch [14] is above lug [15] in baseplate. Use tool No.T10020 [12] or Allen key.
  11. Turn tensioner pulley anti-clockwise to release tension on belt. Use tool No.T10020 [12] or Allen key.
  12. Turn tensioner pulley clockwise until notch aligned with lug in baseplate [15] & [16] . Use tool No.T10020 [12] or Allen key.
  13. Tighten tensioner pulley nut [11] . Tightening torque: 25 Nm.
  14. Turn crankshaft slowly two turns clockwise until timing marks aligned [5] & [6] .
    NOTE: Turn crankshaft last 45° smoothly without stopping.
  15. Ensure notch aligned with lug in baseplate [16] & [15] .
  16. If not: Repeat tensioning procedure.
  17. Install:
    • Timing belt upper cover [9] .
    • RH engine mounting bracket [3] .
    • RH engine mounting bracket bolts [2] .
  18. Tighten RH engine mounting bracket bolts [2] . Tightening torque: 40 Nm.
  19. Lower engine slightly.
  20. Fit and align RH engine mounting [1] :
    • Engine mounting clearance: 16 mm [17] .
    • Ensure engine mounting aligned parallel with engine mounting bracket [18] .
  21. 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.
  22. Install components in reverse order of removal.
  23. Refill cooling system.

NOTE: The manufacturer recommends bleeding the fuel system before starting engine.

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