Audi Workshop Service and Repair Manuals

Detaching timing chains from camshafts, removing and installing chain tensioners

Special tools and workshop equipment required

t	Counterhold tool -T10172- with pin -T10172/2-

t	Adapter -T40058-

t	Locking pin -T40069-

t	Camshaft clamp -T40070- (2x)

t	Locking pin -T40071- (2x)

t  Special wrench -T10035- Removing   Note In the following procedure the camshaft timing chains remain on the engine. If you want to detach the camshaft timing chains completely you must also remove the timing chain cover (bottom) → Chapter. –  Remove cylinder head cover: left-side → Chapter, right-side → Chapter. –  Remove timing chain covers (left and right) → Chapter.

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-fasteners -1- and -2- and take off front noise insulation. Leave rear noise insulation in position.

–  Insert guide pin of adapter -T40058- with the larger-diameter section -arrow 1- pointing towards the engine. The smaller-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 20 Nm. l  The camshaft clamp -T40070- is positioned correctly if the holes for the cylinder head bolts remain free.

–  Unbolt anti-roll bar mountings (left and right) -1- and -2-.

–  Unscrew plug -arrow- from cylinder block.   WARNING To avoid any risk of injury, do not rotate the crankshaft while feeling for the TDC hole with your finger.

–  Screw locking pin -T40069- into bore -1- (tightening torque: 10 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

–  Mark running direction of camshaft timing chain (left-side) with paint. –  Unscrew bolts -1- and -2- for camshaft adjusters using special wrench -T10035-. –  Remove both camshaft adjusters.

–  Unscrew bolts -1- and -2- and remove chain tensioner.

–  Mark running direction of camshaft timing chain (right-side) with paint. –  Unscrew bolts -1- and -2- for camshaft adjusters using special wrench -T10035-. –  Remove both camshaft adjusters.

–  Unscrew bolts -1- and -2- and remove chain tensioner. Installing   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.

l  Drive chain for valve gear installed → Chapter l  Crankshaft locked in TDC position with locking pin -T40069-.

l  Camshaft clamps -T40070- installed on both cylinder heads and tightened to 20 Nm.

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

–  If necessary, clean oil strainer -3- in both chain tensioners. –  Fit new gasket -2- 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-.

–  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-.

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

–  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-.

–  Fit counterhold tool -T10172- with pin -T10172/2- onto camshaft adjuster of inlet camshaft (left-side). –  Pretension camshaft timing chain by pressing counterhold tool in direction of -arrow-. –  At the same time pre-tighten camshaft bolt using special wrench -T10035- and torque wrench. l  Tightening torque: 40 Nm. –  Maintain tension on inlet camshaft and pre-tighten bolt -1- on exhaust camshaft. l  Tightening torque: 40 Nm.

–  Tighten camshaft bolts -1- and -2- at cylinder head (left-side) to final torque. l  Tightening torque: 80 Nm + 90° (1/4 turn further).

–  Fit counterhold tool -T10172- with pin -T10172/2- onto camshaft adjuster of exhaust camshaft (right-side). –  Pretension camshaft timing chain by pressing counterhold tool in direction of -arrow-. –  At the same time pre-tighten camshaft bolt using special wrench -T10035- and torque wrench. l  Tightening torque: 40 Nm. –  Maintain tension on exhaust camshaft and pre-tighten bolt -1- on inlet camshaft. l  Tightening torque: 40 Nm.

–  Tighten camshaft bolts -1- and -2- at cylinder head (right-side) to final torque. l  Tightening torque: 80 Nm + 90° (1/4 turn further).

–  Remove camshaft clamps -T40070- from both cylinder heads.

–  Remove locking pin -T40069-.

–  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 20 Nm. l  The camshaft clamp -T40070- is positioned correctly if the holes for the cylinder head bolts remain free.

–  Screw the locking pin -T40069- directly into the hole. l  The locking pin -T40069- must engage in the locating hole in crankshaft -1-. If it does not, reset valve timing.

–  Remove camshaft clamps from both cylinder heads. –  Remove locking pin. –  Screw plug -arrow- for TDC mark into cylinder block with new seal. Perform further installation in reverse order, paying attention to the following: –  Install anti-roll bar → Rep. Gr.40. –  Install timing chain covers (left and right) → Chapter. –  Install cylinder head cover: left-side → Chapter, right-side → Chapter. Tightening torques

Component	Nm
Chain tensioner to cylinder head	9
Camshaft bolts	80 + 90° 1)2)
Screw plug in cylinder block	14 3)
l  1) Renew bolts. l  2) 90° = one quarter turn. l  3) Install with new seal.