Audi Workshop Service and Repair Manuals

Removing and installing drive chain for valve gear and camshaft timing chain Special tools and workshop equipment required

t  Camshaft bar -T10068 A-

t  Counterhold tool -T10069- t  Sealing compound (black) → Electronic parts catalogue t  Sealing paste → Electronic parts catalogue Removing l  Engine removed → Chapter. l  Engine separated from gearbox → Chapter „Separating engine from manual gearbox“ and → Chapter „Separating engine from direct shift gearbox“. l  Dual-mass flywheel removed → Chapter. l  Intake manifold removed → Rep. Gr.24. l  Cylinder head cover removed → Chapter. l  Thermostat housing removed → Chapter. l  Sump removed → Chapter.

–  Turn the crankshaft to the TDC marking -arrow- in the normal direction of rotation via the securing bolt on the vibration damper.

–  Cams -A- of cylinder 1 must face each other.

–  At the same time insert camshaft bar -T10068 A- in the slots on both camshafts; if necessary, turn the crankshaft 1 rotation further.

–  Mark and unplug the electrical connectors: 1 -  Hall sender -G40- 2 -  Hall sender 2 -G163- 3 -  Inlet camshaft control valve 1 -N205- 4 -  Exhaust camshaft control valve 1 -N318-

–  Unscrew chain tensioner for camshaft timing chain -arrow-.

–  Unscrew bolts -1 ... 3- and remove timing chain cover (top) from cylinder head horizontally. Take care not to damage the cylinder head gasket when removing.

–  Unscrew bolts and remove lower cover -arrow- for timing chains horizontally from cylinder block. Take care not to damage the cylinder head gasket when removing. –  Press out crankshaft oil seal (timing chain end) from the timing chain cover.

–  Mark rotation direction of timing chains with coloured arrows before removing -arrows-.   Caution Avoid damage to timing chains. Do not mark chains by means of centre punch, notch or the like.

–  Unscrew bolts -arrows- and remove guide rail -1-. –  Remove camshaft timing chain from sprocket for intermediate shaft. –  Remove camshaft timing chain carefully from behind the projection of the cylinder head gasket.

–  Loosen bolt -arrow- for chain sprockets on intermediate shaft approx. 1 turn.

–  To do so, apply counterhold tool -T10069- to vibration damper for support.

–  Unscrew chain tensioner for drive chain for valve gear -arrows-.

–  Unscrew bolt -arrow- and remove drive chain together with chain sprockets from intermediate shaft.

Installing l  Tightening torques → Chapter, → Chapter. –  Note the marking for rotation direction -lower arrow- when reinstalling a used drive chain for valve gear.

–  Install drive chain together with large sprocket on intermediate shaft. l  Can only be installed in one position. –  Turn intermediate shaft slightly if large sprocket cannot be fitted. –  Check whether the crankshaft is still positioned at “TDC”: l  The ground-down tooth of the drive chain sprocket must align with the main bearing joint -arrow A-. l  The notch on the sprocket for intermediate shaft must align with the groove -arrow B- on the thrust washer for intermediate shaft.

–  Fit small sprocket to intermediate shaft. l  Can only be installed in one position. –  Renew bolt for chain sprockets of intermediate shaft. –  Hand-tighten bolt -arrow- for chain sprockets.

–  Release locking spline in chain tensioner with a small screwdriver -arrow-.

–  Press tensioning rail against chain tensioner and secure chain tensioner in this position -arrows-.

–  Tighten bolt for chain sprockets -arrow-.

–  Use counterhold tool -T10069- to counterhold bolt for vibration damper.

–  Fit timing chain onto camshaft adjusters. Make sure that the two individual copper-coloured chain links -C- align with markings on camshaft adjuster. In some cases the camshaft adjuster (inlet side) must be turned slightly. –  Fit timing chain onto small chain sprocket. The marking -B- must align with the copper-coloured chain link in the middle -A-.

–  Install guide rail -1- and tighten bolts -arrows-. –  Remove camshaft bar -T10068 A-.

Caution Prevent timing chain from slipping. When turning the crankshaft, it is necessary to press the tensioning rail firmly against the camshaft timing chain manually (to replace function of chain tensioner) -arrow-.

–  Turn crankshaft via the securing bolt for vibration damper 2 rotations in the normal direction of rotation until the marking is at TDC -arrow-.

–  Cams -A- of cylinder 1 must face each other.

–  You should then be able to insert the camshaft bar -T10068 A- in the slots in both camshafts.   Note The marked chain links will now be in an undefined position. If the camshaft bar cannot be inserted: –  Repeat adjustment of valve timing.

–  Clean any old sealing compound from the 3 mm bores -arrows- in the cylinder head gasket.   Note With the cylinder head installed the holes in the cylinder head gasket are only half visible. –  Clean the sealing surfaces on the engine and on both covers; they must be free of oil and grease.

–  Check whether the dowel pins for lower cover for timing chains are inserted in the cylinder block. –  Thinly coat clean surface of lower cover for timing chains -hatched surface in illustration- with sealing paste → Electronic parts catalogue.   Note The lower cover for the timing chains must be installed within 5 minutes after applying the sealing paste.

–  Tighten the bolts securing lower cover -arrow- for timing chains in diagonal sequence in stages.

–  Fill the 3 mm bores -arrows- in the cylinder head gasket with sealing compound (black) → Electronic parts catalogue. –  Renew the oil seals in the upper cover for timing chains → Chapter.

–  Check if the dowel sleeves -2- and -3- are inserted in the upper cover for timing chains. –  Insert a new oil seal -1- and a new seal -4-. –  Thinly coat clean surface of upper cover for timing chains -hatched surface in illustration- with sealing paste → Electronic parts catalogue.

–  Install upper cover for timing chains and tighten bolts in the following sequence: 1 -  Tighten bolts -1- and -2- to 5 Nm. 2 -  Tighten bolts -3- to 23 Nm. 3 -  Tighten bolts -1- and -2- to 10 Nm.

–  Secure chain tensioner -arrow- for camshaft timing chain. –  Turn the crankshaft 2 rotations in the normal direction of rotation and recheck valve timing. –  Install crankshaft oil seal (timing chain end) → Chapter. –  Install cylinder head cover → Chapter. –  Install intake manifold → Rep. Gr.24. –  Install thermostat housing → Chapter. –  Install sump → Anchor. –  Install dual-mass flywheel → Chapter. –  Install engine → Chapter. –  Fill up with engine oil and check oil level → Chapter.