Audi Workshop Service and Repair Manuals

Removing and installing camshaft timing chain

Special tools and workshop equipment required

t	Dial gauge -VAS 6079-

t	Puller -T10094 A-

t	Adapter for dial gauge -T10170-

t	Camshaft clamp -T10171 A-

t	Counterhold tool -T10172-

t	Locking pin -T40011-

t  Spark plug socket and extension -3122 B-

t  Locking pin -T10340-   Note

t  Camshaft clamp -T10171- can also be used instead of camshaft clamp -T10171 A- if an additional hole is drilled as described below. t  Place drilling template -1- onto camshaft clamp -T10171- as shown in illustration. t  Apply a centre punch mark at marking -2-. t  Use a Ø 7 mm drill bit to drill a hole at position marked and deburr hole. t  Apply identification marking “T10171 A” to tool

Removing –  Remove poly V-belt → Chapter. –  Disengage coolant hose -1- at engine cover panel. –  Pull oil dipstick -2- out of guide tube. –  Unscrew bolts -arrows- and remove engine cover panel.

–  Unscrew bolts -2- and detach retaining bracket -1-. –  Unplug electrical connector -3- at charge pressure sender -G31-. –  Release retainers -arrows- and detach air pipe first from throttle valve module -J338- and then from turbocharger. –  Move hoses on air pipe clear.

–  Detach vacuum lines -2- and -3-.   Note Disregard -items 1, 4- and -arrow-.

–  Apply puller -T10094 A- to all ignition coils -arrow-, pull out ignition coils and at the same time unplug electrical connectors at ignition coils for cylinders 1 ... 4. –  Remove spark plug for cylinder 1 with spark plug socket and extension -3122 B-.

–  Unplug electrical connectors -1, 2, 4-, detach wiring duct -3- from camshaft housing and swivel to left side.

–  Unplug electrical connector -arrow- on oil pressure switch -F1-.

–  Remove bolt -1- for earth connection.   Note Disregard -arrows-.

–  Remove bolts -1- and -2- and press coolant pipes (left-side) to left side).   Note Disregard -arrows-.

–  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 holder -T10171 A- must not be used as a counterhold tool.

–  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.

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- with pin -3415/1-. –  Remove bolt and take off poly V-belt pulley. –  Remove timing chain cover → Chapter.

–  Insert 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 holder -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   Note t  Renew bolts for camshaft chain sprocket and camshaft adjuster. t  Renew gaskets and O-rings for camshaft sealing caps.

–  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 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.

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 bush -2- in position on crankshaft. Installation is carried out in the reverse order; note the following: –  Install timing chain cover → Chapter. –  Lubricate O-rings for camshaft sealing caps with oil before installing. –  Install poly V-belt pulley for crankshaft → Chapter.

–  Tighten plug for “TDC” drilling → Fig.. –  Install coolant pipes (left-side) → Chapter. –  Install spark plug → Booklet808. –  Install air pipe → Chapter. –  Install engine cover panel → Fig.. –  Install poly V-belt → Chapter.