How to Replace timing chain on Audio TT 2.0 DTi 2009

Audio TT 2.0 DTi 2009 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Auxiliary drive belt tensioner locking pin – No.T10060A.
• Camshaft sprocket/high-pressure fuel pump sprocket holding tool – Nos.T10172/4.
• Camshaft sprocket/high-pressure fuel pump sprocket locking tool – No.3359 (x 2).
• Crankshaft sprocket locking tool – No.T10050.
• Multi-spline socket – No.T10385.
• Tensioner pulley adjusting tool – No.T10264.
• Tensioner pulley locking tool – No.T10265.

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.

Repair times – hrs

Camshaft drive belt/chain – R & I

2,20

Valve timing procedures

Removal

1. Raise and support front of vehicle.
2. Remove:
   • Engine upper cover.
   • RH front wheel.
   • Engine undershield.
   • RH splash guard.
   • A3 Cabrio/TT: Engine undershield mounting bracket.
3. Disconnect diesel particulate filter (DPF) pressure sensor multi-plug.
4. Reposition:
   • A1/A3: Diesel particulate filter (DPF) pressure sensor bracket.
   • A3: Windscreen washer reservoir filler neck.
5. A3/Q3/TT: Unclip fuel hose from fuel hose support bracket.
6. A3/Q3/TT: Reposition fuel hose support bracket.
7. A3/Q3/TT: Disconnect fuel lift pump multi-plug.
8. A3/Q3/TT: Reposition fuel lift pump support bracket.
9. A3/Q3/TT: Reposition fuel filter. DO NOT disconnect fuel pipes.
10. Disconnect engine coolant temperature (ECT) sensor multi-plug.
11. A1: Move coolant expansion tank to one side. DO NOT disconnect hoses.
12. A3/Q3/TT: Reposition coolant hose from timing belt upper cover. DO NOT disconnect hose.
13. Support engine.
14. Remove:
    • RH engine mounting and bracket.
    • Timing belt upper cover [1] .
    • Auxiliary drive belt. Use tool No.T10060A.

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

    • Crankshaft pulley bolts [2] .
    • Crankshaft pulley [3] .
    • Timing belt centre cover [4] .
    • Timing belt lower cover [5] .
15. Turn crankshaft clockwise to TDC on No.1 cylinder.
16. Camshaft sprocket – type A: Ensure camshaft sprocket window at approximately 12 o’clock position [6] . If not: Turn crankshaft one turn clockwise.
17. Camshaft sprocket – type B: Ensure camshaft sprocket timing hole at 7 o’clock position [7] . If not: Turn crankshaft one turn clockwise.
18. Lock camshaft sprocket [7] . Use tool No.3359.
19. Lock crankshaft sprocket [8] . Use tool No.T10050.
20. Ensure timing marks aligned [9] .
21. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [10] .
22. Slacken camshaft sprocket bolts [11] .
23. Slacken high-pressure fuel pump sprocket bolts [12] . Use tool No.T10385.
    NOTE: Sprockets should turn freely but not tilt.
24. Slacken tensioner pulley nut [13] .
25. Turn tensioner pulley anti-clockwise until locking tool can be inserted [14] . Use tool No.T10264 [15] .
26. Insert locking tool in tensioner pulley [16] . Tool No.T10265.
27. Turn tensioner pulley fully clockwise until it reaches stop [17] . Use tool No.T10264 [15] .
28. Tighten tensioner pulley nut finger tight [13] .
29. Remove timing belt, starting at guide pulley (G3).
    NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

NOTE: Engine must be COLD.

1. Fit new high-pressure fuel pump sprocket bolts [12] . Tighten bolts finger tight.
2. Ensure tensioner pulley locking tool inserted [16] .
3. Ensure camshaft sprocket locking tool located correctly [7] .
4. Ensure crankshaft sprocket locking tool located correctly [10] .
5. Ensure timing marks aligned [9] .
6. Lock high-pressure fuel pump sprocket [18] . Use tool No.3359.
7. If locking tool cannot be inserted [18] : Turn high-pressure fuel pump sprocket as required.
8. Turn camshaft sprocket and high-pressure fuel pump sprocket fully clockwise in slotted holes.
9. Fit timing belt in following order:
   • Crankshaft sprocket.
   • Guide pulley (G1).
   • Tensioner pulley.
   • Camshaft sprocket.
   • Water pump sprocket.
   • Guide pulley (G3).
   • High-pressure fuel pump sprocket.
   • Guide pulley (G2).
10. Slacken tensioner pulley nut [13] .
11. Remove locking tool from tensioner pulley [16] .
12. Ensure tensioner pulley retaining lug is properly engaged [19] .
13. Turn camshaft sprocket anti-clockwise to remove slack from belt between camshaft sprocket and high-pressure fuel pump sprocket. Use tool Nos.T10172/4.
14. Hold camshaft sprocket. Use tool Nos.T10172/4.
15. Tighten camshaft sprocket and high-pressure fuel pump sprocket bolts [11] & [12] . Tightening torque: 20 Nm.
16. Turn tensioner pulley slowly clockwise until pointer aligned with notch [20] .
    NOTE: Ensure tensioner pulley nut does not turn [13] .
17. Hold tensioner pulley. Use tool No.T10264 [15] .
18. Tighten tensioner pulley nut [13] . Tightening torque: 20 Nm + 45°.
19. Remove:
    • Camshaft sprocket locking tool [7] .
    • High-pressure fuel pump sprocket locking tool [18] .
    • Crankshaft sprocket locking tool [8] .
20. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
21. Fit crankshaft sprocket locking tool while slowly turning crankshaft to TDC [8] .
22. Ensure lug of crankshaft sprocket locking tool located in oil seal housing [10] .
23. Ensure timing marks aligned [9] .
24. Ensure camshaft sprocket locking tool can be inserted easily [7] .
    NOTE: DO NOT insert high-pressure fuel pump sprocket locking tool as alignment hole may be slightly misaligned. No adjustment required.
25. Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch [20] . If not: Repeat installation procedure.
26. If camshaft sprocket locking tool cannot be inserted easily [7] :
    • Remove lug of crankshaft sprocket locking tool from hole in oil seal housing.
    • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [21] .
    • Turn crankshaft clockwise until camshaft locking tool can be inserted [7] .
    • Slacken camshaft sprocket bolts [11] .

    NOTE: Lug of crankshaft sprocket locking tool will be positioned to the left or right of hole in oil seal housing.

27. If lug of crankshaft sprocket locking tool is positioned to the left of hole in oil seal housing:
    • Turn crankshaft clockwise until lug and hole aligned [10] .
    • Lock crankshaft sprocket [8] .
    • Ensure timing marks aligned [9] .
    • Hold camshaft sprocket. Use tool Nos.T10172/4.
    • Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.
28. If lug of crankshaft sprocket locking tool is positioned to the right of hole in oil seal housing:
    • Turn crankshaft anti-clockwise until lug of locking tool just passes hole in oil seal housing [21] .
    • Turn crankshaft clockwise until lug and hole aligned [10] .
    • Lock crankshaft sprocket [8] .
    • Ensure timing marks aligned [9] .
    • Hold camshaft sprocket. Use tool Nos.T10172/4.
    • Tighten camshaft sprocket bolts [11] . Tightening torque: 20 Nm.
29. Remove:
    • Camshaft sprocket locking tool [7] .
    • Crankshaft sprocket locking tool [8] .
30. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
31. Ensure locking tools can be inserted [8] & [7] .
32. Ensure timing marks aligned [9] .
33. Hold camshaft sprocket. Use tool Nos.T10172/4.
34. Tighten camshaft sprocket bolts [11] . Tightening torque: 25 Nm.
35. Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
36. Ensure locking tools can be inserted [8] & [7] .
37. Ensure timing marks aligned [9] .
38. Remove locking tools [8] & [7] .
39. Install components in reverse order of removal.
40. Tighten crankshaft pulley bolts [2] . Tightening torque: 10 Nm + 90°. Use new bolts.