Audi Workshop Service and Repair Manuals

Detaching camshaft timing chains from camshafts   Note t  To remove the cylinder head or camshafts, it is sufficient to remove the timing chains from only the camshafts. The chains remain on the engine; only the covers (top left and right) are removed. t  You must adhere to the described procedures even if you are only working on one of the cylinder heads, since the timing adjustment must be performed for both cylinder heads when work is completed.

Special tools and workshop equipment required

t	Locking pin -3242-

t	Removal wedge -3409- (2x)

t	Used oil collection and extraction unit -V.A.G 1782-

t	Special wrench -T10035-

t	Camshaft clamp -T40046- (2x)

t	Setting tool -T40047-

Used oil collection and extraction unit -V.A.G 1782- Drill bit 3.3 mm Ø (2x) Procedure   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing. –  Place used oil collection and extraction unit -V.A.G 1782- under engine and drain engine oil. –  Remove engine: Vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Leave engine on scissor-type assembly platform -VAS 6131 A- with gearbox attached.

–  Unplug electrical connector -1- at throttle valve module -J338-. –  Disconnect hose -3- for crankcase breather system at intake manifold.   Note Item -2- can be disregarded.

–  Detach electrical connectors -1-, -2-, -5- and -6- forwards from brackets on intake manifold. –  Unplug electrical connectors -3- and -4-.

–  Detach vacuum hose -arrow- from T-piece.

–  Unplug connector rail -1- and -5- at injectors. –  On vehicles with fuel return line, disconnect vacuum line -4- at fuel pressure regulator. –  Unscrew securing bolts -2- and -3- for fuel rail. –  Pull fuel rail together with injectors from intake manifold evenly upwards.   Note Make sure the removed injectors do not become soiled.

–  Unscrew engine lifting eye (rear left) -arrows-.

–  Unscrew and remove intake manifold -arrows-.   Note Seal intake ports on cylinder heads with clean cloths.

–  Unscrew sealing cap -arrow- for oil filter housing. –  Remove oil filter element. –  Extract engine oil from oil filter housing using used oil collection and extraction unit -V.A.G 1782-.   Note Place a cloth around the oil filter housing to catch any escaping oil.

–  Remove bolts -arrows-. –  Remove oil filter housing.

–  Remove bolts -1- and -2-. –  Place used oil collection and extraction unit -V.A.G 1782- underneath. –  Detach return pipe from power steering pump -arrow-.

–  Unbolt dipstick guide tube on cylinder head -arrow- and lift out upwards.

–  Remove bolts -1- and -2-. –  Loosen hose clips -arrows- and detach coolant pipe (left-side) from coolant hoses.

–  Remove bolts -1- and -2-. –  Loosen hose clips -arrows- and detach coolant pipe (right-side) from coolant hoses.

–  Unplug electrical connector -2- at coolant temperature sender -G2-/-G62-. –  Unscrew nut -1- and detach electrical wiring harness at coolant pipe (rear).

–  Remove bolts -2 ... 5-. –  Detach coolant pipe (rear).   Note Disregard items marked -1- and -6-.

–  Unscrew securing bolts -1 ... 4- for combination valves for secondary air system.

–  Unscrew nuts -1 ... 12- and remove exhaust manifold (left-side).

–  Detach heat shield (left-side) -arrows-.

–  Unscrew nuts -1 ... 12- and remove exhaust manifold (right-side).

–  Detach heat shield (right-side) -arrows-.

–  Remove bolts -5- and -6- at cylinder head (left-side). –  Unplug electrical connectors -1 ... 4-. –  Pull out ignition coils -arrows-.   Note Use puller -T40039- to remove.

–  Detach crankcase breather hose -arrow-. –  Remove cylinder head cover bolts (left-side) in the sequence -15 ... 1-. –  Remove cylinder head cover.

–  Unscrew bolts -5- and -6- at cylinder head (right-side). –  Unplug electrical connectors -1 ... 4-. –  Pull out ignition coils -arrows-.   Note Use puller -T40039- to remove.

–  Detach crankcase breather hose -arrow-. –  Remove cylinder head cover bolts (right-side) in the sequence -15 ... 1-. –  Remove cylinder head cover.

–  Unplug electrical connector -arrow- for Hall sender 2 -G163- at cylinder head (left-side).

–  Unplug electrical connector -arrow- for Hall sender -G40- at cylinder head (right-side).

–  Unscrew earth wire at cylinder head (right-side) -arrow-. –  Move wiring harness clear.

–  Remove bolts -1 ... 6- and detach timing chain cover (left-side).

–  Unscrew bolts -1 ... 6- and remove timing chain cover (right-side).

–  Turn crankshaft in normal direction of rotation -arrow- to TDC position:

l  The slits -arrows- at front of the camshafts must be parallel to and at the same height as the top edge of cylinder head.

–  If necessary, turn the camshafts at hexagon flats back and forth slightly until camshaft clamp -T40046- can be attached. –  If the camshaft clamp -T40046- cannot be attached, turn crankshaft 1 full turn (360°) in normal rotation direction. –  Remove the camshaft clamp -T40046- again. –  Unscrew plug from sump (top section).

–  Screw locking pin -3242- into bore (20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

–  Press guide rail of chain tensioner for timing chain (left-side) in direction of -arrow- and lock chain tensioner by inserting a 3.3 mm Ø drill bit -item 1-.   Note The following illustrations show the timing drive with the covers completely removed.

–  Unscrew bolts -1- and -2- for camshaft chain sprocket and camshaft adjuster using socket -T10035-. –  Remove camshaft sprocket and camshaft adjuster.   Note t  The camshaft timing chain remain on engine. t  Even if you only need to remove one of the cylinder heads, you will still need to loosen the bolts for camshaft sprockets on both cylinder heads.

–  Press guide rail of chain tensioner for timing chain (right-side) in direction of -arrow- and lock chain tensioner by inserting a 3.3 mm Ø drill bit -item 1-.

–  Unscrew bolts -1- and -2- for camshaft chain sprocket and camshaft adjuster using socket -T10035-. –  Remove camshaft sprocket and camshaft adjuster.   Note t  The camshaft timing chain remain on engine. t  Even if you only need to remove one of the cylinder heads, you will still need to loosen the bolts for camshaft sprockets on both cylinder heads. Installing l  Crankshaft locked in TDC position with locking pin -3242-.   Note t  Renew bolts which are tightened to a specified angle as well as oil seals and gaskets. t  The crankshaft must not be at TDC at any cylinder when the camshaft is turned. Otherwise, there is a risk of damage to valves and piston crowns. t  Fit all cable ties in the original positions when installing.

–  Turn inner section and outer section of both camshaft adjusters in opposite directions until they engage -arrows-. l  You should not be able to turn inner and outer sections in opposite directions once they have engaged (however, a small amount of play is normal). –  Check that camshafts on both cylinder heads are positioned at TDC.

l  The slits -arrows- at front of the camshafts must be parallel to and at the same height as the top edge of cylinder head.

–  Insert camshaft clamp -T40046- in camshafts of left-side cylinder head (if necessary, turn camshafts back and forth slightly at hexagon flats).

–  Insert camshaft clamp -T40046- in camshafts of right-side cylinder head (if necessary, turn camshafts back and forth slightly at hexagon flats). –  Renew all 4 camshaft bolts.

–  Install timing chain (left-side) with camshaft sprocket and camshaft adjuster. –  Screw in bolts -1- and -2- finger-tight. l  It should just be possible to turn the sprocket and camshaft adjuster on the camshaft without axial movement.

–  Install timing chain (right-side) with camshaft sprocket and camshaft adjuster. –  Screw in bolts -1- and -2- finger-tight. l  It should just be possible to turn the sprocket and camshaft adjuster on the camshaft without axial movement.

–  Remove locking pin -3242-.

–  Turn crankshaft back 30° in the opposite direction of normal rotation -arrow-. –  Pull drill bit from locating hole, this releases the chain tensioner (left-side).

–  Insert removal wedge -3409- as shown in illustration and use it to bring chain tensioner into contact. l  Do NOT press too far beyond once contact is made; max. 0.5 mm. –  Pull drill bit from locating hole, this releases the chain tensioner (right-side).

–  Insert removal wedge -3409- as shown in illustration and use it to bring chain tensioner into contact. l  Do NOT press too far beyond once contact is made; max. 0.5 mm.

–  Turn crankshaft in normal direction of rotation -arrow- to TDC position:   Note If you turned the crankshaft beyond TDC, turn it back approx. 30° and set to TDC again.

–  Screw locking pin -3242- into bore (20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

–  Pre-tighten camshaft bolt -1- at exhaust camshaft on cylinder head (left-side). l  Tightening torque: 40 Nm.

–  Lock the Hall sender rotor at camshaft adjuster for inlet camshaft on cylinder head (left-side) using setting tool -T40047-. –  Apply setting tool at bolt -1-. –  Pre-tighten camshaft bolt -2- at inlet camshaft. l  Tightening torque: 40 Nm.

–  Lock the Hall sender rotor at camshaft adjuster for inlet camshaft on cylinder head (right-side) using setting tool -T40047-. –  Apply setting tool at bolt -2-. –  Pre-tighten camshaft bolt -1- at inlet camshaft. l  Tightening torque: 40 Nm. –  Remove setting tool.

–  Pre-tighten camshaft bolt -2- at exhaust camshaft on cylinder head (right-side). l  Tightening torque: 40 Nm.   Note The camshaft clamps must not be used as counterholds when tightening camshaft bolts to final torque.

–  Remove camshaft clamps -T40046- from both cylinder heads.

–  Tighten camshaft bolt -1- at exhaust camshaft on cylinder head (left-side) to final torque. l  Tightening torque: 100 Nm + 90° (1/4 turn further).

–  Lock the Hall sender rotor at camshaft adjuster for inlet camshaft on cylinder head (left-side) using setting tool -T40047-. –  Apply setting tool at bolt -1-. –  Tighten camshaft bolt -2- at inlet camshaft to final torque. l  Tightening torque: 100 Nm + 90° (1/4 turn further).

–  Lock the Hall sender rotor at camshaft adjuster for inlet camshaft on cylinder head (right-side) using setting tool -T40047-. –  Apply setting tool -T40047- at bolt -2-. –  Tighten camshaft bolt -1- at inlet camshaft to final torque. l  Tightening torque: 100 Nm + 90° (1/4 turn further). –  Remove setting tool -T40047-.

–  Tighten camshaft bolt -2- at exhaust camshaft on cylinder head (right-side) to final torque. l  Tightening torque: 100 Nm + 90° (1/4 turn further).

–  Remove locking pin -3242-.

–  Turn crankshaft two rotations in normal direction of rotation -arrow- until it is positioned at TDC again.

l  The slits -arrows- at front of the camshafts must be parallel to and at the same height as the top edge of cylinder head.

–  Screw locking pin -3242- into bore (20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

–  Attach camshaft clamp -T40046- on camshafts at cylinder head (left-side).

–  Apply camshaft clamp -T40046- to camshafts on cylinder head (right-side). If the camshaft clamps cannot be inserted: –  Repeat adjustment. –  Take out removal wedges -3409-. –  Remove camshaft clamp -T40046- from both cylinder heads. –  Remove locking pin -3242-. –  Secure screw plug for the TDC mark into the top section of the sump with a new seal. Remaining installation steps are carried out in reverse sequence; note the following: –  Install timing chain covers → Anchor. –  Install engine: vehicles with manual gearbox → Chapter; vehicles with automatic gearbox → Chapter. –  Fill up with engine oil and check oil level → Chapter. Tightening torques

Component	Nm
Camshaft bolts	100 + 90° → Note → Note
Screw plug in top section of sump	35
Oil drain plug	50

1)  90° equals a 1/4 turn. 2)  Renew bolts.