Audi Workshop Service and Repair Manuals

Removing and installing camshaft timing chain Special tools and workshop equipment required

t  Counterhold tool -3415- with pin -3415/2-

t  Counterhold tool -T10172-

t  Locking pin -T10340-

t  Camshaft clamp -T10414-

Removing –  Press release tabs on hose (right-side) and disconnect both hoses -1- from non-return valve. –  Remove bolt -2- and pull non-return valve out of camshaft housing.

–  Rotate crankshaft in normal direction of rotation -arrow- until camshaft is at „TDC“.

l  Grooves -arrows- on camshaft should be positioned as shown in illustration.

–  Remove bolts -1- and -3- and take off bracket -2- for coolant pipe (right-side).

–  Unscrew plug -arrow- for „TDC“ hole on cylinder block.

–  Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 Nm.   Note The locking pin -T10340- locks the crankshaft only in the direction of engine rotation. –  Remove timing chain cover (top) → Chapter. –  Remove timing chain cover (bottom) → Chapter.

–  Slide camshaft clamp -T10414- into camshaft housing as far as stop and screw bolt -1- in by hand until it makes contact.

–  Unscrew chain tensioner -arrow- for camshaft timing chain.   Caution If a used timing chain rotates in the opposite direction when it is refitted, this can cause breakage. Mark running direction of timing chain with coloured arrows for re-installation. Avoid damage to camshaft. The camshaft clamp -T10414- must not be used as a counterhold tool.

–  Apply counterhold tool -T10172- to camshaft chain sprocket and remove bolt -1-. –  Detach camshaft chain sprocket together with camshaft timing chain. –  Pull out camshaft timing chain from below. Installing Tightening torques l  → Chapter „Camshaft timing chain - exploded view“. l  → Chapter „Cylinder head - exploded view“.   Note t  Renew the bolts tightened with specified tightening angle. t  Renew the seal and O-rings. –  Check „TDC“ position of camshaft and crankshaft:

l  Camshaft clamp -T10414- must be fitted to camshaft housing.   Caution Avoid damage to camshaft. The camshaft clamp -T10414- must not be used as a counterhold tool.

l  Locking pin -T10340- is screwed into cylinder block as far as stop and tightened to 30 Nm. l  Crankshaft is turned in normal direction of rotation until it makes contact with locking pin -T10340- = „TDC“ position.

–  Fit camshaft timing chain according to marks applied when removing. –  Fit camshaft timing chain -1- onto crankshaft chain sprocket -2- from below and guide chain upwards between guide rail and tensioning rail. –  Use a screwdriver -3- or similar tool to prevent the camshaft timing chain from dropping out.

–  Fit camshaft timing chain -1- onto camshaft chain sprocket -2-. –  Position camshaft chain sprocket on camshaft and fit bolt for camshaft chain sprocket without tightening. l  It should just be possible to turn the camshaft chain sprocket on the camshaft without axial movement.   Note Disregard -item 3-.

–  Screw in and tighten chain tensioner -arrow- for timing chain.

Caution Avoid damage to camshaft. The camshaft clamp -T10414- must not be used as a counterhold tool. –  Tighten bolt -1- initially to 50 Nm (counterhold at camshaft chain sprocket using counterhold tool -T10172-).   Note The bolt for the camshaft chain sprocket is not tightened to its final torque until the valve timing has been checked.

Checking adjustment –  Fit poly V-belt pulley onto crankshaft. –  Screw in old bolt for poly V-belt pulley and tighten to 50 Nm (counterhold with counterhold tool -3415- and pin -3415/2-).   Note Illustration shows installation position with timing chain cover fitted.

–  Unscrew bolt -1- and remove camshaft clamp -T10414-.

–  Remove locking pin -T10340-.

–  Turn crankshaft 2 revolutions in normal direction of rotation -arrow- until camshaft is at „TDC“ again.

l  Grooves -arrows- on camshaft should be positioned as shown in illustration.

–  Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 Nm.

–  Turn crankshaft in normal direction of rotation -arrow- until it makes contact with locking pin.

l  It should be possible to insert camshaft clamp -T10414- into camshaft housing as far as stop and lock it in place with bolt -1-. –  If camshaft clamp -T10414- cannot be inserted into camshaft housing as far as stop, repeat adjustment procedure → Anchor. –  If it is possible to insert camshaft clamp -T10414- completely, take off camshaft clamp again. –  Remove locking pin -T10340-.

–  Remove old bolt for poly V-belt pulley (counterhold with counterhold tool -3415- and pin -3415/2-). Installation is carried out in the reverse order; note the following: –  Install timing chain cover (bottom) → Chapter. –  Install timing chain cover (top) → Chapter. –  Install bracket for coolant pipe (right-side) → Chapter.