Audi Workshop Service and Repair Manuals

Removing and installing camshaft timing chains

Special tools and workshop equipment required

t	Locking pin -3242-

t	Special wrench -T40049-

t	2x Adjustment pin -T40060-

t	Adapter -T40061-

t	Adapter -T40062-

t	Nuts M12 (2x)

t	Drill bit 3.3 mm Ø (2x)

Removing l  Gearbox removed.   Caution Avoid damage to valves and piston crowns. The crankshaft and camshafts must only be turned with the chain drive mechanism fully installed. –  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-.   Note

t  The adjustment pin -T40060- has a flat -2- which makes it easier to insert when the locating bores in the camshaft and cylinder head are not exactly in line. t  The adjustment pin is inserted initially so that the side pin -1- is perpendicular to the imaginary line between the adjustment pin and the centre of the camshaft. t  To obtain the correct „TDC“ position, the side pin -1- must then be turned 90° -arrow- so it is in line with the imaginary line between the adjustment pin and the centre of the camshaft.

Caution Irreparable damage can be caused if the camshaft timing chains slip. Turn crankshaft only in direction of engine rotation. –  Rotate crankshaft to „TDC“: l  It should be possible to lock the camshafts with the adjustment pins -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 1 (right-side).

l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 2 (left-side).

–  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.

–  Wrap insulating tape around tip and shaft of 3.3 mm Ø drill bit to avoid cuts. –  Press tensioning rail of camshaft timing chain tensioner (left-side) in direction of -arrow- and lock chain tensioner by inserting 3.3 mm Ø drill bit -item 1-.   Caution If a used timing chain rotates in the opposite direction when it is refitted, this can cause breakage. Mark running direction of timing chain with coloured arrows for re-installation. –  Remove adjustment pin -T40060- from both camshafts.

–  Unscrew bolt -3- and remove tensioning rail. –  Remove bolts -1- for guide rail and -2- for camshaft chain sprocket. –  Detach camshaft chain sprocket, guide rail and camshaft timing chain (left-side).

–  Wrap insulating tape around tip and shaft of 3.3 mm Ø drill bit to avoid cuts. –  Press guide rail of camshaft timing chain tensioner (right-side) in direction of -arrow- and lock chain tensioner by inserting 3.3 mm Ø drill bit -item 1-.

Caution If a used timing chain rotates in the opposite direction when it is refitted, this can cause breakage. Mark running direction of timing chain with coloured arrows for re-installation. –  Remove bolts -1- for chain tensioner and bolts -2- and -3- for camshaft chain sprocket. –  Detach camshaft chain sprocket, chain tensioner and camshaft timing chain (right-side).

Installing l  Tightening torques → Chapter „Camshaft timing chains - exploded view“ l  Crankshaft -1- locked in „TDC“ position with locking pin -3242-. l  Drive chain for valve gear installed → Chapter   Note t  Renew the seal on the screw plug for the „TDC“ mark. t  Renew the bolts tightened with specified tightening angle.   Caution Avoid damage to valves and piston crowns. The crankshaft must not be at „TDC“ at any cylinder when the camshafts are turned.

–  Check that camshafts on both cylinder heads are positioned at „TDC“. l  It should be possible to lock the camshafts with the adjustment pins -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 1 (right-side).

l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 2 (left-side). –  Remove adjustment pin -T40060- from both camshafts.

Caution Avoid damage to valves and piston crowns. The crankshaft must not be at „TDC“ at any cylinder when the camshafts are turned.   Note If the pins cannot be inserted in the camshafts, the camshafts can be turned slightly using adapter -T40061-. To do so, screw securing bolts for camshaft sprocket into camshaft.

–  Install camshaft timing chain (left-side) with camshaft chain sprocket, guide rail and tensioning rail. l  The elongated holes in the camshaft chain sprocket must be aligned centrally over the tapped holes in the camshaft. –  Tighten bolts -1- and -3- for guide rail and tensioning rail. –  Fit both bolts -2- for camshaft chain sprocket without tightening. l  It should just be possible to turn the sprocket on the camshaft without axial movement. –  Use adjustment pin -T40060- to lock camshaft (left-side). l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. –  Pull drill bit -4- out of locating hole, this releases the chain tensioner (left-side).

–  Install camshaft timing chain (right-side) with camshaft chain sprocket and chain tensioner. l  The elongated holes in the camshaft chain sprocket must be aligned centrally over the tapped holes in the camshaft. –  Tighten bolts -1- for chain tensioner. –  Fit both bolts -2- for camshaft chain sprocket without tightening. l  It should just be possible to turn the sprocket on the camshaft without axial movement. –  Use adjustment pin -T40060- to lock camshaft (right-side). l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. –  Pull drill bit -3- out of locating hole, this releases the chain tensioner (right-side).

–  Apply a torque of 20 Nm to camshaft sprocket (right-side) in clockwise direction -arrow- using a torque wrench and adapter -T40062- and maintain this torque. –  Tighten bolts -1- and -2-. –  Remove adapter -T40062- and adjustment pin -T40060-. –  Tighten remaining bolts for camshaft sprocket (right-side).

–  Apply a torque of 15 Nm to camshaft sprocket (left-side) in clockwise direction -arrow- using a torque wrench and adapter -T40062- and maintain this torque. –  Tighten bolts -1- and -2-. –  Remove adapter -T40062- and adjustment pin -T40060-. –  Tighten remaining bolts for camshaft sprocket (left-side).

–  Remove locking pin -3242-.

Checking valve timing   Caution Irreparable damage can be caused if the camshaft timing chains slip. Turn crankshaft only in direction of engine rotation. –  Turn crankshaft two rotations using special wrench -T40049- until it is again positioned just before „TDC“.   Note Disregard -arrows-.

–  While turning in this direction, lock crankshaft -1- with locking pin -3242-. Tighten locking pin to 20 Nm.   Caution The crankshaft must be exactly in „TDC“ position to ensure accurate valve timing adjustment. If crankshaft has been turned past „TDC“ position, turn crankshaft two further rotations until it is again positioned just before „TDC“. Then turn further in the same direction and lock crankshaft with locking pin -3242-.

–  Check that camshafts on both cylinder heads are positioned at „TDC“. l  It should be possible to lock the camshafts with the adjustment pins -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 1 (right-side).

l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft on cylinder bank 2 (left-side).

Adjusting valve timing –  If the pin cannot be inserted in one of the camshafts, loosen all bolts -arrows- of relevant camshaft chain sprocket approx. 1 turn.

–  Apply adapter -T40061- to the heads of the loosened bolts. –  Turn camshaft slightly backwards and forwards with adapter -T40061- until adjustment pin -T40060- can be inserted. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. –  With adapter -T40061- and adjustment pin -T40060- still in position, tighten bolts on camshaft sprocket to approx. 5 Nm. –  Remove adjustment pin -T40060- and adapter -T40061-. –  Tighten bolts for camshaft chain sprocket to final torque. –  Repeat procedure on other cylinder bank if necessary. –  Remove locking pin -3242-. –  Check valve timing once again → Anchor. Remaining installation steps are carried out in reverse sequence; note the following:

–  Tighten plug for „TDC“ drilling in sump (top section) → Chapter. –  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.