Audi Workshop Service and Repair Manuals

Removing and installing chain for auxiliary drives

Special tools and workshop equipment required

t	Locking pin -3242-

t	Diesel injection pump locking pin -3359-

t	Special wrench -T40049-

t	Nuts M12 (2x)

t	Drill bit, Ø 3.3 mm

Removing l  Gearbox removed. –  Remove drive plate → Chapter. –  Remove timing chain covers: left-side → Chapter, right-side → Chapter, bottom → Chapter.

Caution Risk of damage to drive chain if thread of bolt exceeds specified length. t  Use bolts with a maximum thread length -a- of 22 mm to attach special wrench -T40049-. t  If no suitable bolts are available, position suitable washer(s) under bolt head so that remaining thread length does not exceed 22 mm.

–  Attach special wrench -T40049- at rear end of crankshaft using 2 bolts -arrows-.

–  Use extended hexagon socket wrench with ball head and unscrew plug -arrow- from sump (top section).

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

Caution If a used chain for auxiliary drives rotates in the opposite direction when it is refitted, this can cause breakage. Mark running direction of chain for auxiliary drives with coloured arrows for re-installation. –  Lock balance shaft at rear of engine with diesel injection pump locking pin -3359- and loosen bolts -arrows- for balance shaft sprocket.

–  Wrap insulating tape around tip and shaft of 3.3 mm Ø drill bit to avoid cuts. –  Press guide rail of chain tensioner in direction of -arrow- and lock chain tensioner by inserting 3.3 mm Ø drill bit -item 4-. –  Remove bolts -1- and -2- and take out chain tensioner, balance shaft sprocket -3- and chain.

Installing l  Tightening torques → Chapter „Drive chain for auxiliary drives - exploded view“ l  Crankshaft -1- locked in „TDC“ position with locking pin -3242-.

–  Lock balance shaft -arrow- at rear of engine with diesel injection pump locking pin -3359-

–  Install chain tensioner with chain and balance shaft sprocket. l  The elongated holes in the sprocket -3- must be aligned centrally over the tapped holes in the balance shaft. –  Tighten bolts -1- and -2- for chain tensioner.   Note Disregard -item 4- and -arrow-.

–  Fit bolts -arrows- for chain sprocket without tightening. l  It should just be possible to turn the sprocket on the balance shaft without axial movement.

–  Pull drill bit out of locating hole, this releases the chain tensioner. –  Press against guide rail of chain tensioner in direction of -arrow- using a screwdriver, and at the same time tighten bolts -1- securing chain sprocket. –  Pull diesel injection pump locking pin -3359- out of balance shaft. Remaining installation steps are carried out in reverse sequence; note the following: –  Install timing chain covers: left-side → Chapter, right-side → Chapter, bottom → Chapter. –  Install drive plate → Chapter. –  Fill up with engine oil and check oil level → Booklet811, → Booklet812 or → Booklet818.