kelisko

Procuring replacement parts

Valve cover bolts (replacing only damaged, stripped bolts), 2 per side for me, total 4
Part number: 06B 103 831 J
Link (Audi genuine part): ECS Tuning

Driver's side upper valve cover gasket
Part number: 06E 103 483 G
Link (Audi genuine part): ECS Tuning

Passenger's side upper valve cover gasket
Part number: 06E 103 484 G
Link (Audi genuine part): ECS Tuning

Timing chain cover bolts, 8 per side, total 16:
Part number: N 100 292 05
Link (Audi genuine part): ECS Tuning

Timing chain cover silicone sealant
Part number: Permatex 82180
Link: ECS Tuning

Cam adjuster bolts, 2 per side, total 4
Part number: N 910 428 02
Link (Audi genuine part): ECS Tuning

Timing chain tensioner bolts, 6 per side, total 12
Part number: N 101 243 06
Link (Audi genuine part): ECS Tuning

Driver's side upper timing chain tensioner
Part number: 06E 109 217 AN
Link (Audi genuine part): ECS Tuning

Passenger's side upper timing chain tensioner
Part number: 06E 109 218 AQ
Link (Audi genuine part): ECS Tuning

Vacuum pump bolts, total 3
Part number: N 101 243 06
Link (Audi genuine part): ECS Tuning

Vacuum pump outer gasket
Part number: 06E 145 215 A
Link (Audi genuine part): ECS Tuning

Vacuum pump inner gaskets
Part number: N/A
Note: The outer gasket in this kit is not a good one. Go for the genuine one in the link above.
Link: eBay

Vacuum pump upper hose clamp
Part number: ECS 5574K12
Link: ECS Tuning

Cam girdle bolts, 22 on driver's side and 20 on passenger's side, total 42
Part number: N 105 540 05
Link (Audi genuine part): ECS Tuning

Driver's side lower valve cover gasket (Spark plugs and solenoid seal)
Part number: 06E 103 649 A
Link (Audi genuine part): ECS Tuning

Passenger's side lower valve cover gasket (Spark plugs and solenoid seal)
Part number: 06E 103 650 A
Link (Audi genuine part): ECS Tuning

Cam girdle anaerobic sealant
Part number: D 154 103 A1
Link (Audi genuine part): ECS Tuning

Engine plug o-ring
The manual says to replace it. I couldn't locate the part number and I did not replace it.

Spark plugs, 3 per side, total 6
Par number: Bosch 101905631GKT3
Link (OEM): ECS Tuning

Oil filter kit
Part number: 06E 115 562 C
Link (Audi genuine part): ECS Tuning

6L synthetic oil
Use the best quality synthetic engine oil you have available and that you can afford.

kelisko

Procuring special tools

3.2L V6 FSI Timing Tool Kit
Part number: BT40070KIT
Kit contains:
2 Camshaft locators: T40070
1 Counter-holder tool T10172
2 Counter-holder tool pins T10172/2 and 2 other pins
1 Engine locking pin T40069
2 Upper timing chain tensioner securing pins T40071
1 Crankshaft turning adapter T40058
1 Multi-point socket T10035
Link: ECS Tuning

Crankshaft turning adaptor for 1/2" drive wrench
Part number: CT3659
Note: I was not sure how to use the adaptor (T40058) which came with the kit above because I couldn't attach it to my 1/2" drive long wrench. I have used this one which I could attach to my 1/2" drive long wrench to instead.
Link: eBay

kelisko

Other useful tools

Telescoping Magnet Pick-Up Tool (you NEED this!!!)
Part number: 016121SCH03A
Note: This tool saved me from dropping bolts either behind the engine or inside the engine during removal or installation of bolts. This is a need-to-have tool which will save you big time! I will show you later how I used it.
Link: ECS Tuning

Torx T-30 driver bit with a 1/4" drive holder (magnetic preferred)
Note: You won't be able to go anywhere without the holy T-30. Vacuum pump, throttle body, valve covers, timing chain covers, timing chain tensioners, cam girdle are all bolted down with T-30 head bolts. In addition, you need a 1/4" drive holder as well as adapters and extensions so that you can attach it to a 1/4" or 3/8" drive wrench or torque wrench. The mechanic tool set I included below has non-magnetic Torx drivers and extensions as well as a screwdriver holder but not a 1/4" drive holder. My T-30 bit and holder are not magnetic but I wish they were during the job. Go for magnetic ones if you don't have any and are planning to procure them.

Extended 3/8" Drive Spark Plug Socket
Part number: S-3858-125
Link: ECS Tuning

1/4" Drive Torque Wrench 2 - 25 Nm
Part number: TIT23146
Link: ECS Tuning

1/2" Drive Torque Wrench 15 - 200 Nm
Part number: TW-12450
Link: ECS Tuning

1/4", 3/8" and 1/2" Drive Adapter Set
Part number: KDT81217
Link: ECS Tuning

Mirror
You need a small size mirror you can place behind the engine without having to hold it to be able to see what you are doing in there. Useful during removing and installing timing chain tensioners and timing chain covers.

Torch
You definitely need a torch to better see behind the engine.

Mechanics Tool Set
Part number: Craftsman 938165
Note: This is a very useful tool set that I own since 5 years now. It has most of the necessary tools you need to do your mechanic jobs. The 1/4" drive wrench included in this set is small and useful for removing and installing T-30 bolts behind the engine in obstructed locations.
Link: eBay

09mazda6

As usual Kelisko, you are setting a very high bar for the rest of us both. looking forward to the rest of this thread.

kelisko

Torque specifications

Camshafts guide frame (cam girdle) to cylinder head
8 Nm + 90 degrees (1/4 turn)
Replace bolts

Upper timing chain tensioner to cylinder head
9 Nm

Camshaft adjuster to camshaft
40 Nm then 80 Nm + 90 degrees (1/4 turn)
Replace bolts

Upper timing chain cover to cylinder head
5 Nm + 90 degrees (1/4 turn)
Replace bolts

Sealing plug to cylinder block
14 Nm
Replace gasket

Vacuum pump to cylinder head
9 Nm

Cylinder head cover (valve cover) to cylinder head
9 Nm
Replace bolts if damaged

Spark plugs
30 Nm

Throttle body to upper intake manifold
5 Nm

Oil drain plug to oil pan
30 Nm

Oil filter cover
25 Nm

Sway bar nuts
25 Nm

Sway bar links bolts
40 Nm + 90 degrees (1/4 turn)
Replace bolts and nuts.

kelisko

Considerations

You don't have to replace your upper valve cover gaskets if you did so recently.

You don't have to replace your upper timing chain tensioner if you did so recently.

Park the car in a safe location and expect this job to last days, if not weeks.

G-Can

buddy, you are great!

Im fighting with massive leaks on mine, replaced majority of this list, next is a thorough de greasing of the engine, and washing away all the oil that has splattered all over the place under engine.

Ruined my driveway how many oil patches is there now.

so far, I replaced... valve cover gaskets, timing chain tensioners and seals, vacuum pump rebuild, with inner and outer seal, camshaft solenoid O rings, oil filter housing gasket...
what am I still missing... this is ridicolous...

kelisko

You are missing the green part and it is likely you did the red part wrong. Check the pictures and illustrations I posted above.

The green part is what most people never did and what people almost never mention. Read this thread since the beginning carefully and you will understand.

It it very easy to do the red part the wrong way because there isn't much space. Stay tuned. I will explain later how I did mine.

G-Can

red part ws done by audi mechanic. that should be fine.

green part wasnt done, I will have to use scope camera to see under if it leaks there. I doubt it.

kelisko

Getting it started

First of all, I unlocked the car, made sure all the doors are unlocked and disconnected the battery. I usually disconnect the positive terminal.
EDIT: It is safer to disconnect the negative terminal instead. It's what I do now.

Then I blocked the trunk from shutting accidentally by placing a thick piece of rag. With the battery disconnected, if the trunk is shut, you would not be able to open it which you don't want to happen.
EDIT: Well, wrong. You can unlock and open the trunk with the key. Now I know: youtu.be/RyCXtrclWN8

When I am not working on the car, I cover the trunk opening area with a large towel so that dirt does not get inside and I gently place the lid on it as shown in the picture below.