Audi A1 Service and Repair Manuals

Removing and installing camshaft timing chain

Special tools and workshop equipment required

t	Spark plug socket and extension -3122 B-

t	Counterhold tool -3415- with pins -3415/1-

t	Dial gauge -VAS 6079-

t	Puller -T10094 A-

t	Adapter for dial gauge -T10170-

t	Camshaft clamp -T10171 A-

t	Hose clip pliers -VAS 6362-

t	Assembly tool -T10118-

t	Counterhold tool -T10172-

t	Locking pin -T10340-

t	Locking pin -T40011-

Removing –  Pull off engine cover panel (front) -arrows- and remove towards front.

–  Release fasteners -arrows- and detach air pipe -1-.

–  Remove bolts -1 and 3-. –  Release hose clip -2-, detach air pipe (top right) and remove air hose.

–  Remove bolt -1- and move coolant pipe clear at intake resonator -2-.

–  Remove bolts -arrows-. –  Release hose clip -2- and push coolant pipe (left-side) slightly towards left.   Note Disregard -items 1, 3-.

–  Unplug electrical connector -2-. –  Detach vacuum hoses -1-.

–  Unplug electrical connector -4-. –  Remove bolts -1 and 3-. –  Press release tabs and disconnect crankcase breather hoses -arrows-. –  Release hose clip -2- and disconnect hose at activated charcoal filter. –  Detach hoses.

–  Apply puller -T10094 A- to ignition coil for cylinder 1, pull out ignition coil and at the same time unplug electrical connector at ignition coil for cylinder 1. –  Remove spark plug for cylinder 1 with spark plug socket and extension -3122 B-.

–  Using assembly tool -T10118-, unplug electrical connector -arrow- at oil pressure switch -F1-.

–  Remove bolts -arrows- and detach sealing caps -1- and -2-.

–  Screw adapter for dial gauge -T10170- into spark plug hole as far as the stop. –  Insert dial gauge -VAS 6079- with extension -T10170/1- as far as the stop and secure using locking nut -arrow-. –  Rotate crankshaft in normal direction of rotation to „TDC“. l  „TDC“ = maximum measured value on dial gauge.

l  The threaded holes -arrows- in the camshafts must be positioned as shown in illustration. Turn crankshaft one turn (360°) if necessary.

–  Insert camshaft clamp -T10171 A- into holes in camshafts as far as stop. l  The locking pins -arrows 1- must engage in the holes -arrows 2-. l  The inscription „TOP“-arrow 3- should be legible from above.

–  To secure the camshaft clamp -T10171 A-, screw in an M6 bolt -arrow- hand-tight, but do not tighten.   Caution Avoid damage to camshafts. The camshaft clamp -T10171 A- must not be used as a counterhold tool.

–  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.

Caution Risk of damage to engine. To prevent the crankshaft chain sprocket from slipping off the drive lug, do not rotate the crankshaft after the poly V-belt pulley has been detached. –  Loosen bolt for poly V-belt pulley using counterhold tool -3415- and pin -3415/1-. –  Remove bolt and take off poly V-belt pulley. –  Remove timing chain cover → Chapter.

–  Insert bearing bush -2- and screw in crankshaft pulley bolt -1- hand-tight to secure chain sprocket on crankshaft.

–  Press tensioning rail -2- in direction of -arrow- and use locking pin -T40011- to lock piston for chain tensioner -1-.   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. Do not mark timing chain by means of centre punch, notch or the like. Avoid damage to camshafts. The camshaft clamp -T10171 A- must not be used as a counterhold tool. Risk of damage to thread. The camshaft adjuster central bolt has a left-hand thread.

–  Loosen bolt -2- for camshaft adjuster -1- and bolt -4- for camshaft chain sprocket -5-, using counterhold tool -T10172- to counterhold on camshaft chain sprocket. –  Detach camshaft chain sprocket together with camshaft timing chain -3-.   Note Leave camshaft adjuster on camshaft. Installing l  Tightening torques → Chapter „Camshaft timing chain - exploded view“   Note t  Renew the bolts tightened with specified tightening angle. t  Renew gaskets and O-rings for camshaft sealing caps. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue.

–  Check „TDC“ position of camshaft and crankshaft: l  The camshaft clamp -T10171 A- must be fitted to camshaft housing.   Caution Risk of damage to valve gear. The camshafts must not be moved axially when turning.

l  Locking pin -T10340- screwed into cylinder block as far as stop and tightened to 30 Nm. l  Turn crankshaft in direction of engine rotation until it makes contact with locking pin -T10340-.

Caution Risk of damage to thread. The camshaft adjuster central bolt has a left-hand thread. –  Fit bolt -2- for camshaft adjuster -1- without tightening. l  It should just be possible to turn the adjuster on the camshaft without axial movement.

–  Fit camshaft timing chain according to marks applied when removing. –  Fit camshaft timing chain -1- together with camshaft chain sprocket -2- for exhaust camshaft onto crankshaft sprocket and camshaft adjuster. –  Fit bolt -3- for camshaft chain sprocket without tightening. l  It should just be possible to turn the camshaft chain sprocket on the camshaft without axial movement.

–  Remove locking pin -T40011- from chain tensioner -1- and tension camshaft timing chain. –  Check „TDC“ position of camshaft and crankshaft again → Anchor.   Note Disregard -arrow-.

Caution Risk of damage to thread. The camshaft adjuster central bolt has a left-hand thread. –  Tighten bolt -2- for camshaft adjuster -1- to 40 Nm and bolt -4- for camshaft chain sprocket -5- to 50 Nm, using counterhold tool -T10172- to counterhold on camshaft chain sprocket.   Note t  Do not tighten bolts for camshaft adjuster and camshaft chain sprocket to final torque before checking timing again. t  When tightening the bolts, the crankshaft must not turn and the camshaft timing chain -3- must remain tensioned on both sides. –  Detach camshaft clamp -T10171 A-. –  Remove locking pin -T10340-.

–  Turn crankshaft 2 revolutions in direction of engine rotation and set to „TDC“. l  „TDC“ = maximum measured value on dial gauge.   Note t  If the crankshaft was turned more than 0.01 mm beyond „TDC“, turn back the crankshaft approx. 45° in the opposite direction of normal rotation. Then turn crankshaft in normal direction of rotation to „TDC“. t  Permissible deviation from TDC: ± 0.01 mm. t  Disregard -arrow-.

–  Screw locking pin -T10340- into cylinder block as far as stop and tighten to 30 Nm. –  Turn crankshaft in direction of engine rotation until it makes contact with locking pin.

–  Insert camshaft clamp -T10171 A- into holes in camshafts as far as stop. l  The locking pins -arrows 1- must engage in the holes -arrows 2-. l  The inscription „TOP“-arrow 3- should be legible from above. –  If camshaft clamp -T10171 A- cannot be fully inserted into holes in camshafts, repeat adjustment. –  If it is possible to insert camshaft clamp -T10171 A- completely, take off camshaft clamp again. –  Remove locking pin -T10340-.

Caution Risk of damage to thread. The camshaft adjuster central bolt has a left-hand thread. –  Tighten bolt -2- for camshaft adjuster -1- and bolt -4- for camshaft chain sprocket -5- and turn further through specified angle to final setting (counterhold at camshaft chain sprocket using counterhold tool -T10172-).   Note Disregard -item 3-. –  Turn crankshaft 2 revolutions in direction of engine rotation and set to „TDC“. –  Check adjustment → Anchor; repeat adjustment if necessary.

Caution Risk of damage to engine. To prevent the crankshaft chain sprocket from slipping off the drive lug, do not rotate the crankshaft after the poly V-belt pulley has been detached. –  Remove bolt for poly V-belt pulley -1-.   Note Leave bearing bush -2- in position on crankshaft. Installation is carried out in the reverse order; note the following: –  Install timing chain cover → Chapter. –  Install sealing caps for camshafts → Chapter. –  Install poly V-belt pulley for crankshaft → Chapter. –  Install coolant pipe (left-side) → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install air pipe (top right) → Chapter. –  Install air hoses with screw-type clips → Fig..