Audi Workshop Service and Repair Manuals

Removing timing chains from camshafts - vehicles up to 03.2007

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	Camshaft clamp -T40070- (2x)

t	Locking pin -T40071- (2x)

t  Adapter -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 timing chain covers (left and right) → Chapter. –  Remove cylinder head cover: left-side → Chapter, right-side → 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.

–  Mark positions of camshaft adjusters with paint for re-installation. –  Unscrew camshaft adjuster bolts -1- and -2- at cylinder head (left-side). –  Remove both camshaft adjusters.

–  Mark positions of camshaft adjusters with paint for re-installation. –  Unscrew camshaft adjuster bolts -1- and -2- at cylinder head (right-side). –  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.   Note

The chain tensioner is shown removed in the following illustration. –  First completely release guide rail of chain tensioner for camshaft timing chain -arrow- (carefully move timing chain to side). l  The piston -1- of the tensioner must be fully extended, so that the locking device is released.   Note 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.

–  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-.   Note

Re-install camshaft adjuster (left-side) in the same position as before (pay attention to marks applied when removing). –  Renew the camshaft bolts. –  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-.   Note

Re-install camshaft adjuster (right-side) in the same position as before (pay attention to marks applied when removing). –  Renew the camshaft bolts. –  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-.   Note

A second mechanic is required for the following work steps. –  Fit adapter -T40079- onto camshaft adjuster of inlet camshaft on cylinder head (left-side). –  Apply torque wrench -V.A.G 1332- with tool insert -V.A.G 1332/9- to adapter -T40079-. –  Tension camshaft adjuster by applying a torque of 40 Nm in direction of -arrow- and maintain tension. –  At the same time pre-tighten bolt -1- on exhaust camshaft. l  Tightening torque: 60 Nm. –  Maintain tension on inlet camshaft and pre-tighten bolt -2- on inlet camshaft. l  Tightening torque: 60 Nm.

–  Fit adapter -T40079- onto camshaft adjuster of exhaust camshaft on cylinder head (right-side). –  Apply torque wrench -V.A.G 1332- with tool insert -V.A.G 1332/9- to adapter -T40079-. –  Tension camshaft adjuster by applying a torque of 40 Nm in direction of -arrow- and maintain tension. –  At the same time pre-tighten bolt -1- on inlet camshaft. l  Tightening torque: 60 Nm. –  Maintain tension on exhaust camshaft and pre-tighten bolt -2- on exhaust camshaft. l  Tightening torque: 60 Nm.

–  Detach adapter -T40079-. –  Remove camshaft clamps -T40070- from both cylinder heads.

–  First tighten camshaft bolt -1- and then camshaft bolt -2- on cylinder head (left-side) to final torque. l  Tightening torque: 80 Nm + turn 90° further.

–  First tighten camshaft bolt -1- and then camshaft bolt -2- on cylinder head (right-side) to final torque. l  Tightening torque: 80 Nm + turn 90° further.

–  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) → Chapter. –  Install cylinder head cover: left-side → Chapter, right-side → Chapter. Tightening torques → Chapter