Removal & Installation Audi TT 8N

1. On ATC and AWP engines, disconnect charge air cooler duct at bottom of right-hand crossmember. (Scheme 1) To identify engine, check engine code located on a pad on engine block near bellhousing of transmission. On all models, remove center and right-hand noise insulation panels from under vehicle. (Scheme 2)
2. Rotate serpentine drive belt tensioner clockwise (as viewed from front of engine) to relieve belt tension. Remove serpentine drive belt and tensioner. (Scheme 3)
3. Remove cooling system expansion tank and power steering reservoir bolts, leaving hoses attached, secure expansion tank and reservoir out of way.
4. Remove vacuum hose connecting fuel evaporative canister to throttle body. Unplug electrical connectors on coolant expansion tank and fuel evaporative canister. Remove upper timing belt cover. (Scheme 4).
5. Remove weight of engine from engine mounts by installing Support Bracket (10-222) or equivalent. Engine may be supported from below using floor jack. Use care not to damage components.
6. Turn crankshaft sprocket center bolt in normal direction of rotation to align the crankshaft vibration damper at TDC of No. 1 cylinder. Ensure camshaft sprocket timing mark is aligned with mark on rear timing belt cover. (Scheme 5) Slightly lift engine.
7. Remove 4 bolts around center bolt on vibration damper. Remove vibration damper. It is NOT necessary to remove crankshaft center bolt. DO NOT move crankshaft during removal of vibration dampener.
8. Remove center and bottom timing belt covers. Remove bolts from engine console and right-hand engine support arm. (Scheme 6) Remove engine console and right-hand engine support arm.
9. Remove bolts for engine support, but do not remove engine support. (Scheme 7) If reusing old timing belt, mark belt with arrow to indicate original direction of rotation.
10. Screw a M5 x 55 stud into the timing belt tensioner bracket. (Scheme 8) Install hex nut and washer onto stud.
11. SLOWLY turn hex nut on stud to compress timing belt tensioner. Compress tensioner just enough so that a locking pin or drill bit can be inserted through the tensioner body, locking the tensioner in place. Pull out timing belt through space between engine support and cylinder block.

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Installation

1. Install timing belt onto crankshaft sprocket. Install lower timing belt cover. Install vibration damper pulley, making sure notch in center hole of vibration damper is aligned with projection on crankshaft sprocket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-155235-S39729545622003061100000).
2. Ensure camshaft and crankshaft timing marks are still aligned. (Scheme 5) Install timing belt on water pump, tensioner pulley and camshaft sprocket.
3. Remove locking pin or drill bit from timing belt tensioner. Remove M5 x 55 stud from tensioner bracket. Turn crankshaft 2 complete revolutions in normal direction of rotation. Align camshaft and crankshaft timing marks.
4. Install engine right-hand engine support arm and console using NEW bolts. Adjust engine console and right-hand engine support arm so clearance is about 0.50" (13 mm). (Scheme 6)
5. Remove Engine Support Bracket (10-222) or floor jack from under vehicle. Install center and upper timing belt covers. Install serpentine belt tensioner and serpentine belt.
6. Install coolant expansion tank and power steering reservoir. Install vacuum line between fuel evaporative canister and throttle body. To install remaining components, reverse removal procedure.