Audi Workshop Service and Repair Manuals

Removing and installing drive chain for auxiliary drives Special tools and workshop equipment required

t  Special wrench -T40049-

t  Locking pin -T40071- t  Drill bit, Ø 8 mm Removing l  Gearbox removed. –  Remove timing chain cover (bottom) → Chapter.

Caution Make sure drive chain is not damaged. Place a washer under the bolt heads to make sure the drive chain does not get trapped by the bolts. –  Attach special wrench -T40049- at rear end of crankshaft using 2 old securing bolts -arrows- for drive plate.

–  Unscrew plug -arrow- for “TDC” marking from cylinder block. –  Rotate crankshaft in normal direction of rotation to “TDC”.   Note

t  The bore provided for locking the crankshaft is difficult to see when the engine is installed. t  Therefore, turn the engine until the small notch -1- on the left-side of the vibration damper (as seen in the direction of travel) is in line with the housing joint -2- between the cylinder block and the retaining frame. This makes it easier to screw in locking pin -T40069-. t  The marking on the vibration damper is only a visual aid. The exact “TDC” position can only be obtained by screwing in the locking pin -T40069-.

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

–  Press guide rail of chain tensioner in direction of -arrow- and lock chain tensioner by inserting locking pin -T40071-.   Caution If a used drive chain rotates in the opposite direction when it is refitted, this can cause breakage. Mark running direction of drive chain with paint for re-installation. Do not mark drive chain by means of centre punch, notch or the like. –  Unscrew bolts -3- and detach chain sprocket from balance shaft. –  Remove bolts -1- and -2- and take off chain tensioner with drive chain.

Installing l  Tightening torques → Chapter, → Fig.. l  Crankshaft -1- locked in “TDC” position with locking pin -T40069-.

–  Install chain tensioner with drive 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 using 8 mm Ø drill bit -item 2-. 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. –  Fit bolts -1- and -3- 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 out locking pin -T40071- to release chain tensioner. –  Press against guide rail of chain tensioner -arrow- using a screwdriver, and at the same time tighten bolts -1- and -3- securing chain sprocket. –  Pull drill bit -2- out of balance shaft. Remaining installation steps are carried out in reverse sequence; note the following: –  Install timing chain cover (bottom) → Chapter. –  Fill up with engine oil and check engine oil level → Chapter.