Audi Workshop Service and Repair Manuals

Removing and installing camshaft timing chains - vehicles up to 03.2007 Removing l  Engine separated from gearbox → Chapter, engine attached to scissor-type assembly platform -VAS 6131 A- or secured to engine and gearbox support → Chapter. l  Engine oil drained → Booklet803 or → Booklet805. –  Remove clutch pressure plate → Rep. Gr.30. –  Remove dual-mass flywheel → Chapter. –  Remove cylinder head cover: left-side → Chapter, right-side → Chapter. –  Remove timing chain covers (left and right) → Chapter. –  Remove intake manifold → Rep. Gr.24. –  Remove oil filter housing → Chapter. –  Remove timing chain cover (bottom) → Chapter. –  Remove camshaft timing chains from camshafts → Chapter.

–  Mark running direction of camshaft timing chain (left-side) with paint. –  Unscrew bolts -1- and -2- and remove chain tensioner (left-side) and camshaft timing chain (left-side).   Note Make sure that the tensioner piston remains in the chain tensioner and does not drop to the ground.

–  Mark running direction of camshaft timing chain (right-side) with paint. –  Unscrew bolts -1- and -2- and remove chain tensioner (right-side) and camshaft timing chain (right-side).   Note Make sure that the tensioner piston remains in the chain tensioner and does not drop to the ground. Installing   Note t  Note the correct installation position if the tensioning element has been removed from the chain tensioner: drilling in base of housing faces chain tensioner and piston faces tensioner rail. t  Renew the bolts tightened with specified tightening angle. t  Renew gasket.   Caution Avoid damage to valves and piston crowns. The crankshaft must not be at “TDC” at any cylinder when the camshafts are turned.

–  First completely release guide rail of removed chain tensioners for camshaft timing chains (left and right) -arrow-. l  The piston -1- of the tensioner must be fully extended, so that the locking device is released.

–  Press guide rails of chain tensioners for camshaft timing chains (left and right) inwards in direction of -arrow- as far as the stop. Then lock chain tensioners by inserting locking pin -T40071-.

–  If necessary, clean oil strainer -2- in both chain tensioners. –  Fit new gasket -3- to rear of chain tensioner -1-.

–  Install chain tensioner on cylinder head (left-side) and position camshaft timing chain as shown in the illustration. –  Tighten bolts -1- and -2-.

–  Install chain tensioner on cylinder head (right-side) and position camshaft timing chain as shown in the illustration. –  Tighten bolts -1- and -2-. Remaining installation steps are carried out in reverse sequence; note the following: –  Position timing chains on camshafts → Anchor. –  Install timing chain cover (bottom) → Chapter. –  Install crankshaft oil seal (gearbox end) → Chapter. –  Install oil filter housing → Chapter. –  Install intake manifold → Rep. Gr.24. –  Install timing chain covers (left and right) → Anchor. –  Install cylinder head cover: left-side → Chapter, right-side → Chapter. –  Install dual-mass flywheel → Chapter. –  Install clutch pressure plate → Rep. Gr.30. –  After installing engine, fill up with engine oil and check oil level → Booklet803 or → Booklet805. Tightening torque → Chapter