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How to Replace timing gears on Audi A3 8P MK2 1.6 TDI 2009-

Special tools

  • Camshaft alignment tool – No.T40094.
  • Camshaft holding tool – No.T40095.
  • Camshaft sprocket hub holding tool – No.T10051.
  • Camshaft sprocket hub puller – No.T10052.
  • Camshaft/high-pressure fuel pump locking tool – No.3359.
  • Crankshaft sprocket locking tool – No.T10050.
  • Two-piece exhaust camshaft gear alignment tool – No.T40096/1.

General precautions

  • Disconnect battery earth lead.
  • Remove glow plugs to ease turning engine.
  • Turn engine in normal direction of rotation (unless otherwise stated).
  • Observe tightening torques.
  • If fitted: Mark position of crankshaft position (CKP) sensor before removal.
  • Do NOT turn crankshaft via camshaft or other gears.
  • Do NOT turn crankshaft or camshaft with timing gear(s) removed.
How to Replace timing gears on Audi A3 1.6 TDI 2009-
How to Replace timing gears on Audi A3 1.6 TDI 2009-

Valve timing procedures

  • Removal/installation of timing gears requires:
      • Timing belt removal.
      • Removal of camshafts.
  • Engine at TDC on No.1 cylinder.
  • Fit crankshaft sprocket locking tool [1] .
  • Ensure timing marks aligned [2] .
  • Install camshaft sprocket locking tool [3] .
  • Fit inlet camshaft on camshaft alignment tool [4] .
  • Ensure camshaft alignment tool engages in end of camshaft [5] .
  • Fit exhaust camshaft on camshaft alignment tool [6] .
  • Ensure camshaft alignment tool engages in end of camshaft [7] .
  • Ensure indents on camshafts are facing outwards [8] .
  • If fitted: Align gear teeth of two-piece exhaust camshaft gear with camshaft gear alignment tool [9] .
  • Move inlet camshaft in direction of arrow to engage teeth of camshaft gears [10] .
  • Fit camshaft housing on camshafts [11] .
  • Retain camshafts in position with camshaft holding tool [12] .
  • Disengage camshaft alignment tool from end of camshafts [5] & [7] .
  • Remove camshaft housing and camshafts held in position with special tools from camshaft alignment tool.
  • Place camshaft housing with camshafts and special tools on cylinder head [11] .
  • Ensure crankshaft sprocket locking tool located correctly [1] .
  • Ensure timing marks aligned [2] .
  • Refit camshaft housing [11] .
  • Remove special tools [9] & [12] .

NOTE: Allow 30 minutes after installing camshafts before starting engine to prevent engine damage.

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