Audi Workshop Service and Repair Manuals

Removing timing chains from camshafts - vehicles from 03.2007 onwards

Special tools and workshop equipment required

t	Locking pin -3242-

t	Torque wrench -V.A.G 1332-

t	Socket -V.A.G 1332/9-

t	Adapter -T40058-

t	2x Camshaft clamp -T40070-

t	2x Locking pin -T40071-

t  Key -T40079- Removing l  Engine removed and in position on scissor-type assembly platform -VAS 6131 A- with gearbox attached.   Note In the following procedure the camshaft timing chains remain on the engine. –  Remove cylinder head covers: left-side → Chapter, right-side → Chapter. –  Remove timing chain covers (left and right) → Chapter.

–  Insert guide pin of adapter -T40058- as follows: l  The smaller-diameter section -arrow 1- faces the engine. l  The larger-diameter section -arrow 2- faces the adapter.

–  Using adapter -T40058- turn the crankshaft in the normal direction of rotation -arrow- to “TDC”.

l  The threaded holes -arrows- in the camshafts must face upwards.

–  Fit camshaft clamps -T40070- to both cylinder heads and tighten bolts -arrows- to 25 Nm. l  The camshaft clamp -T40070- is positioned correctly if the holes for the cylinder head bolts remain free.

–  Unscrew plug from sump (top section). –  Screw locking pin -3242- into bore (tightening torque: 20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

–  Press guide rail of chain tensioner for camshaft timing chain (left-side) inwards as far as the stop using a screwdriver -1-. Then lock chain tensioner by inserting locking pin -T40071-.   Note The chain tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure.

–  Press guide rail of chain tensioner for camshaft timing chain (right-side) inwards as far as the stop using a screwdriver -1-. Then lock chain tensioner by inserting locking pin -T40071-.   Note The chain tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure.

Caution Risk of damage to engine. Block off the opening in the valve timing housing with a clean cloth to prevent small items from dropping into the engine. –  Unscrew bolts -1- and -2- at cylinder head (left-side) and remove both camshaft adjusters.

–  Mark positions of camshaft adjusters with paint for re-installation. –  Unscrew bolts -1- and -2- at cylinder head (right-side) and remove both camshaft adjusters. Installing   Note Renew the bolts tightened with specified tightening angle.   Caution Avoid damage to valves and piston crowns. The crankshaft must not be at “TDC” at any cylinder when the camshafts are turned.

l  Drive chain for valve gear installed → Chapter l  Crankshaft locked in “TDC” position with locking pin -3242-.

l  Camshaft clamps -T40070- installed on both cylinder heads and tightened to 25 Nm -arrows-.

–  Re-install camshaft adjusters on cylinder head (left-side) in the same position as before (pay attention to marks applied when removing). –  Position camshaft timing chain on drive chain sprocket and camshaft adjusters and loosely screw in bolts -1 and 2-. l  It should just be possible to turn both camshaft adjusters on the camshaft without axial movement. –  Remove locking pin -T40071-.

–  Re-install camshaft adjusters on cylinder head (right-side) in the same position as before (pay attention to marks applied when removing). –  Position camshaft timing chain on drive chain sprocket and camshaft adjusters and loosely screw in bolts -1 and 2-. l  It should just be possible to turn both camshaft adjusters on the camshaft without axial movement. –  Remove locking pin -T40071-.

–  Fit key -T40079- onto camshaft adjuster of inlet camshaft on cylinder head (left-side). –  Apply torque wrench -V.A.G 1332- with socket -V.A.G 1332/9- to key -T40079-. –  Have a 2nd mechanic apply a torque of 40 Nm to camshaft adjuster in direction of -arrow-. –  Tighten bolts as follows while keeping camshaft adjuster under tension:

1.  Pre-tighten bolt -1- on inlet camshaft to 60 Nm. 2.  Pre-tighten bolt -2- on exhaust camshaft to 60 Nm.

–  Fit key -T40079- onto camshaft adjuster of exhaust camshaft on cylinder head (right-side). –  Apply torque wrench -V.A.G 1332- with socket -V.A.G 1332/9- to key -T40079-. –  Have a 2nd mechanic apply a torque of 40 Nm to camshaft adjuster in direction of -arrow-. –  Tighten bolts as follows while keeping camshaft adjuster under tension:

1.  Pre-tighten bolt -1- on inlet camshaft to 60 Nm. 2.  Pre-tighten bolt -2- on exhaust camshaft to 60 Nm.

–  Detach key -T40079-. –  Remove camshaft clamp -T40070- from both cylinder heads -arrows-.

–  Tighten camshaft adjuster bolts on cylinder head (left-side) as follows:

1.  Tighten bolt -1- on inlet camshaft to final tightening torque. 2.  Tighten bolt -2- on exhaust camshaft to final tightening torque.

–  Tighten camshaft adjuster bolts on cylinder head (right-side) as follows:

1.  Tighten bolt -1- on inlet camshaft to final tightening torque. 2.  Tighten bolt -2- on exhaust camshaft to final tightening torque.

–  Remove locking pin -3242-.

–  Using adapter -T40058-, turn crankshaft two rotations in normal direction of rotation -arrow- until crankshaft is at “TDC” again.   Note If you turned the crankshaft beyond “TDC”, turn it back approx. 30° and set to “TDC” again.

l  The threaded holes -arrows- in the camshafts must face upwards.

–  Fit camshaft clamps -T40070- to both cylinder heads and tighten bolts -arrows- to 25 Nm. l  The camshaft clamp -T40070- is positioned correctly if the holes for the cylinder head bolts remain free.

–  Screw the locking pin -3242- into the hole (20 Nm). l  The locking pin -3242- must engage in the locating hole in crankshaft. If it does not, reset valve timing. –  Remove camshaft clamps from both cylinder heads. –  Remove locking pin -3242-. –  Secure screw plug for “TDC” mark into sump (top section) with a new seal → Chapter. Remaining installation steps are carried out in reverse sequence; note the following: –  Install timing chain covers (left and right) → Anchor. –  Install cylinder head covers: left-side → Chapter, right-side → Chapter. Tightening torques → Chapter