Audi Workshop Service and Repair Manuals

Removing timing chains from camshafts

Special tools and workshop equipment required

t	Torque wrench -V.A.G 1332-

t	Socket -V.A.G 1332/9-

t	Special wrench -T10035-

t	Counterhold tool -T10172-

t	Adapter -T40058-

t	Locking pin -T40069-

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

t  2x Locking pin -T40071-

t  2x Camshaft clamp -T40133-

Removing   Note In the following procedure the camshaft timing chains remain on the engine. –  Remove relevant cylinder head cover: left-side → Chapter; right-side → Chapter. –  Remove timing chain covers (left and right) → Chapter. –  Remove noise insulation panels -1- and -2- → Rep. Gr.66.

Vehicles not equipped with continued coolant circulation pump -V51-: –  Remove bolt -1- and nut -3- and detach strut -2- (left-side) for lock carrier.

–  Position used oil collection and extraction unit -V.A.G 1782- below engine. –  Remove bolts -arrows- and tie up oil cooler to one side with coolant hoses -1- and -2- attached. Vehicles with continued coolant circulation pump -V51-: –  Remove continued coolant circulation pump -V51- → Chapter and oil cooler → Chapter.

All vehicles (continued): –  Insert guide pin of adapter -T40058- as follows: l  The larger-diameter section -arrow 1- faces towards the engine. l  The smaller-diameter section -arrow 2- faces the adapter.

–  Turn crankshaft with adapter -T40058- in normal direction of rotation -arrow- to “TDC position”.

–  Unscrew plug -arrow- for “TDC” marking from cylinder block.   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-.

l  The threaded holes -arrows- in the camshafts must face upwards.

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

–  Fit camshaft clamps -T40133- onto both cylinder heads and tighten bolts -arrows- to 25 Nm.   Note The illustration shows the left-side cylinder head.

–  Press guide rail of chain tensioner for camshaft timing chain (left-side) inwards as far as the stop using a screwdriver -1-. Then lock chain tensioner by inserting locking pin -T40071-.   Note The chain tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure.

–  Press guide rail of chain tensioner for camshaft timing chain (right-side) inwards as far as the stop using a screwdriver -1-. Then lock chain tensioner by inserting locking pin -T40071-.   Note The chain tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure.

Caution Avoid damage to camshaft. Do NOT use camshaft clamp -T40133- as a counterhold tool when loosening camshaft adjuster bolts -1-. –  Fit counterhold tool -T10172- with pin -T10172/2- to counterhold on corresponding camshaft adjuster and loosen with special wrench -T10035-.

–  Mark position of camshaft adjusters with paint for re-installation.   Caution Risk of damage to engine. Block off the opening in the valve timing housing with a clean cloth to prevent small items from dropping into the engine. –  Unscrew bolts -1- and -2- on cylinder head (left-side) and remove both camshaft adjusters.

–  Mark position of camshaft adjusters with paint for re-installation. –  Unscrew bolts -1- and -2- on cylinder head (right-side) and remove both camshaft adjusters. Installing l  Tightening torques → Chapter, → Fig..   Note t  Renew the bolts tightened with specified tightening angle. t  Renew the O-ring on the screw plug for the “TDC” marking.   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 -T40069-.

l  Camshaft clamps -T40133- installed on both cylinder heads and tightened to 25 Nm -arrows-.   Note The illustration shows the left-side cylinder head.

Caution Risk of damage to engine. When performing the following steps, make sure to fit camshaft adjusters so that the grooves -1- and -4- are aligned with the adjustment areas (ground surfaces) -2- and -3-.   Note

Re-install camshaft adjusters on cylinder head (left-side) in the same position as before (pay attention to marks applied when removing). –  Fit timing chain (left-side) onto drive chain sprocket and camshaft adjusters and fit bolts -1- and -2- without tightening. 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 adjusters on cylinder head (right-side) in the same position as before (pay attention to marks applied when removing). –  Fit timing chain (right-side) onto drive chain sprocket and camshaft adjusters and fit bolts -1- and -2- without tightening. l  It should just be possible to turn both camshaft adjusters on the camshaft without axial movement. –  Remove locking pin -T40071-.

–  Apply counterhold tool -T10172- with pin -T10172/2- onto camshaft adjuster of inlet camshaft (left-side). –  Have a 2nd mechanic apply tension to camshaft timing chain by pressing counterhold tool in direction of -arrow-. –  Tighten bolts as follows while keeping camshaft adjuster under tension:

1.  Pre-tighten bolt on inlet camshaft to 80 Nm. 2.  Pre-tighten bolt -1- on exhaust camshaft to 80 Nm.

–  Apply counterhold tool -T10172- with pin -T10172/2- onto camshaft adjuster of exhaust camshaft (right-side). –  Have a 2nd mechanic apply tension to camshaft timing chain by pressing counterhold tool in direction of -arrow-. –  Tighten bolts as follows while keeping camshaft adjuster under tension:

1.  Pre-tighten bolt on exhaust camshaft to 80 Nm. 2.  Pre-tighten bolt -1- on inlet camshaft to 80 Nm.

–  Remove camshaft clamps -T40133- from both cylinder heads -arrows-.   Note The illustration shows the left-side cylinder head.

–  Tighten camshaft adjuster bolts on cylinder head (left-side) as follows:

1.  Tighten bolt -1- on inlet camshaft to final tightening torque. 2.  Tighten bolt -2- on exhaust camshaft to final tightening torque.

–  Tighten camshaft adjuster bolts on cylinder head (right-side) as follows:

1.  Tighten bolt -1- on inlet camshaft to final tightening torque. 2.  Tighten bolt -2- on exhaust camshaft to final tightening torque.

–  Remove locking pin -T40069-.

–  Using adapter -T40058-, turn crankshaft 2 revolutions in normal direction of rotation -arrow- until crankshaft is at “TDC” again.   Note If you turn the crankshaft beyond “TDC” by mistake, turn it back approx. 30° and set to “TDC” again.

l  The threaded holes -arrows- in the camshafts must face upwards.

–  Fit camshaft clamps -T40133- onto both cylinder heads and tighten bolts -arrows- to 25 Nm.

–  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 -T40069-. Remaining installation steps are carried out in reverse sequence; note the following: –  Install timing chain covers (left and right) → Chapter. –  Install cylinder head covers: left-side → Chapter; right-side → Chapter. –  Install continued coolant circulation pump -V51- → Chapter. –  Install oil cooler → Chapter. –  Install strut for lock carrier → Rep. Gr.50. –  Install front noise insulation → Rep. Gr.66.