Audi Workshop Service and Repair Manuals

Removing and installing drive chain for auxiliary drives on vehicles up to 04.2006

Special tools and workshop equipment required

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

t	Special wrench -T40049-

t	Locking pin -T40069-

t	Locking pin -T40071-

t	Drill bit, Ø 8 mm

Removing l  Gearbox removed. –  Vehicles with manual gearbox: remove clutch pressure plate → Rep. Gr.30 and dual-mass flywheel → Chapter. –  Vehicles with multitronic gearbox: Remove damper unit → Chapter and flywheel → Chapter. –  Vehicles with automatic gearbox: remove drive plate → Chapter.   Note After the gearbox has been removed the engine is supported with support bracket -10-222 A- and the stop for the torque reaction support is detached.   WARNING Make sure that the lock carrier is installed on the vehicle before performing the following steps. –  Detach support bracket -10-222 A- from engine (attached previously in order to remove gearbox).

–  Secure stop for torque reaction support -arrows- (tighten bolts to 28 Nm). –  Remove timing chain covers (left and right) → Chapter. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil. –  Remove timing chain cover (bottom) → Chapter.   Caution Place a washer under the bolt heads to make sure the chain does not get trapped by the bolts.

–  Attach special wrench -T40049- at rear end of crankshaft using two old securing bolts -arrows- for dual-mass flywheel.

Vehicles with manual gearbox: –  Unbolt anti-roll bar mountings (left and right) -1- and -2-. –  Pivot anti-roll bar downwards.

All vehicles: –  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. –  Turn crankshaft in normal direction of rotation to TDC position.

–  Screw locking pin -T40069- into bore (tightening torque: 20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin.

–  Mark running direction of drive chain for auxiliary drives with paint. –  Press guide rail of chain tensioner in direction of -arrow- and lock chain tensioner by inserting locking pin -T40071-. –  Remove bolts -1 ... 3- and take out chain tensioner, balance shaft sprocket and chain.

Installing l  Crankshaft -1- locked in TDC position with locking pin -T40069-.

–  Install chain tensioner with chain and balance shaft sprocket. –  Wrap insulating tape around tip and shaft of 8 mm Ø drill bit to avoid cuts. –  Lock balance shaft in TDC position with Ø 8 mm drill bit -item 1-. l  The elongated holes in the balance shaft sprocket must be aligned centrally over the threaded holes in the balance shaft. If necessary move chain one tooth further. –  Tighten bolts for chain tensioner. –  Screw in bolts -2- for chain sprocket, but do not tighten. l  It should just be possible to turn the sprocket on the balance shaft without axial movement. –  Pull locking pin -T40071- out to release chain tensioner. –  Press against guide rail of chain tensioner -arrow- using a screwdriver, and at the same time tighten bolts -2- securing chain sprocket. –  Pull drill bit -item 1- out of balance shaft. Perform further installation in reverse order, paying attention to the following: –  Install timing chain cover (bottom) → Chapter. –  Install oil filter housing → Chapter. –  Install timing chain covers (left and right) → Chapter. –  Install crankshaft oil seal (timing chain end) → Chapter. –  Vehicles with manual gearbox: Install dual-mass flywheel → Chapter and pressure plate → Rep. Gr.30. –  Vehicles with multitronic gearbox: Install flywheel → Chapter and damper unit → Chapter. –  Vehicles with automatic gearbox: install drive plate → Chapter. –  Install anti-roll bar → Rep. Gr.40. –  Fill up with engine oil and check oil level → Booklet803 or → Booklet805. Tightening torques

Component	Nm
Chain tensioner to cylinder block	6 + 45° 1)2)
Chain sprocket for balance shaft to balance weight	15 + 90° 1)3)
Screw plug in cylinder block	14 4)
l  1) Renew bolts. l  2) 45° = one eighth turn. l  3) 90° = one quarter turn. l  4) Install with new seal.