Camshaft Timing Chain, Removing And Installing

WARNING: This page is about a different car, the 2011 Audi Q7, 2010 Audi Q7, and 2009 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Locking Pin 3242
Crankshaft Key T40049
2 - Camshaft Adjustment Pins T40060
Camshaft Correction Tool T40061
Chain Sprocket Tensioner T40062
3.3 mm diameter drill bit (quantity: 2)

Removal

The transmission is removed.

CAUTION:

Risk of damaging valves and piston crowns.

Turn the crankshaft and camshafts only with the chain drive completely installed.

-- Remove the timing chain cover lower section. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Attach the Crankshaft Key T40049 the back of the crankshaft using two old drive plate bolts -arrows-.

Fig 1: Identifying Key T40049 At Rear On Crankshaft And 2 Old Bolts For Dual-Mass Flywheel

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NOTE:

The Camshaft Adjustment Pins T40060 has a flat part -2- which makes it easier to insert if the camshaft and the cylinder head are slightly offset.

Fig 2: Identifying Adjustment Pin T40060

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Insert the pin so that the bolt -1- is perpendicular to the camshaft axle.

Move the bolt -1- 90° -arrow- so that it is perpendicular to the camshaft axle and it is possible to attain the correct "TDC" position.

Fig 3: Checking Camshafts TDC Position

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CAUTION:

Components could be damaged by the camshaft timing chain jump off.

Only rotate the crankshaft in the direction of engine rotation.

-- Use the Crankshaft Key T40049 to rotate the crankshaft to "TDC" :

-- Check whether camshafts of both cylinder heads stand in "TDC" position.

It must be possible to secure the camshafts with the Camshaft Adjustment Pins T40060.
The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 1 (right).

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 2 (left).

Fig 4: Identifying Perpendicular Pin -Arrow- On Adjustment Pin T40060
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-- Remove the bolt -arrow- for the "TDC" marking from the upper part of the oil pan by using a long hex socket wrench with a ball head.

Fig 5: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Install the Crankshaft Holder3242 in the hole and tighten to 20 Nm. Turn the crankshaft -1- back and forth slightly to completely center the bolt, if necessary.

Fig 6: Identifying Crankshaft Holder 3242

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-- To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Fig 7: Identifying Chain Tensioner Secured Using 3.3 Mm Diameter Drill Bit

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-- Push the tensioning track for the left camshaft timing chain tensioner in the -direction of the arrow- and secure the chain tensioner with a 3.3 mm drill bit -item 1-.

CAUTION:

If the running direction is reversed on a used camshaft timing chain, it could be damaged.

Paint arrows to mark the timing chain running direction so it can be installed again.

-- Remove the Camshaft Adjustment Pins T40060 from both camshafts.

-- Remove the bolt -3- and remove the tensioning rail.

Fig 8: Identifying Bolts -1- For Guide Rail And Bolts -2- For Camshaft Chain Sprocket

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-- Remove the bolt -1- for the guide rail and -2- for the camshaft chain sprocket.

-- Remove the camshaft chain sprocket, guide rail and left camshaft timing chain.

-- To protect against cuts, wrap the point and the cutting edges on a 3.3 mm drill bit with insulating tape.

Fig 9: Identifying 3.3 mm Diameter Drill Bit -1- To Install Chain Tensioner Guide Rail On Right Camshaft Timing Chain

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-- Push the chain tensioner guide rail for the right camshaft timing chain in the -direction of the arrow- and secure the chain tensioner with a 3.3 mm drill bit -1-.

Fig 10: Identifying Chain Tensioner Guide Rail Installed On Right Camshaft Timing Chain

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CAUTION:

If the running direction is reversed on a used camshaft timing chain, it could be damaged.

Paint arrows to mark the timing chain running direction so it can be installed again.

-- Remove the chain tensioner -2- and camshaft chain sprocket -3- bolts -1-.

-- Remove the camshaft chain sprocket, chain tensioning and right camshaft timing chain.

Installation

Fig 11: Identifying Crankshaft Holder 3242

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Tightening specifications. Refer to CAMSHAFT TIMING CHAINS OVERVIEW .
Secure the crankshaft -1- in "TDC" position using the Locking Pin 3242.
The timing mechanism drive chain is installed. Refer to TIMING MECHANISM DRIVE CHAIN, REMOVING AND INSTALLING .

NOTE:

Replace any bolts that were tightened with an additional turn.

CAUTION:

Risk of damaging valves and piston crowns.

If camshafts are rotated, crankshaft may not rest with any piston at "TDC".

-- Check whether camshafts of both cylinder heads stand in "TDC" position.

Fig 12: Identifying Check Of Camshafts For Both Cylinder Heads In TDC Position And Adjustment Pin T40060

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It must be possible to secure the camshafts with the Camshaft Adjustment Pins T40060.
The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 1 (right).

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 2 (left).

Fig 13: Identifying Perpendicular Pin -Arrow- On Adjustment Pin T40060
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-- Remove the Camshaft Adjustment Pins T40060 from both camshafts.

Fig 14: Identifying Adapter T40061 And Adjustment Pin T40060

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CAUTION:

Risk of damaging valves and piston crowns.

If camshafts are rotated, crankshaft may not rest with any piston at "TDC".

NOTE:

If the camshafts are not secured, it is possible to correct them slightly with the Camshaft Correction Tool T40061 by Installation the camshaft chain sprocket on the camshaft.

-- Install the left camshaft timing chain with the camshaft chain sprocket, the guide rail and the tensioning rail.

Fig 15: Identifying Left Camshaft Timing Chain, Camshaft Chain Sprocket, Guide Rail And Tensioning Rail

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The slots in the camshaft chain sprocket must be at the middle position in relation to the threaded holes in the camshaft.

-- Tighten the bolts -1- and -3- for the guide rail and the tensioning rail.

-- Install both camshaft chain sprocket bolts -2- loosely.

It must still be possible to rotate the camshaft chain sprocket on the camshaft and it must not tip.

-- Secure the left camshaft with the Camshaft Adjustment Pins T40060.

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft.

-- Pull the drill -4- out of the alignment hole, thereby releasing the chain tensioner.

-- Install the right camshaft timing chain with the chain sprocket and chain tensioner.

Fig 16: Identifying Drill Bit -4- And Alignment Hole

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The slots in the camshaft chain sprocket must be at the middle position in relation to the threaded holes in the camshaft.

-- Tighten the chain tensioner bolts -1-.

-- Install both camshaft chain sprocket bolts -2- loosely.

It must still be possible to rotate the camshaft chain sprocket on the camshaft and it must not tip.

-- Secure the right camshaft with the Camshaft Adjustment Pins T40060.

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft.

-- Pull the drill -3- out of the alignment hole, thereby releasing the right chain tensioner.

-- Pre-tighten the right camshaft chain sprocket using the Chain Sprocket Tensioner T40062 and torque wrench to 20 Nm in -direction of arrow- and hold.

Fig 17: Identifying Bolts -1 And 2-, Torque Wrench, Adapter T40062 And Adjustment Pin T40060

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-- Fasten bolts -1- and -2-.

-- Remove the Chain Sprocket Tensioner T40062 and Camshaft Adjustment Pins T40060.

-- Tighten the remaining bolts for the right camshaft chain sprocket.

-- Pre-tighten the left camshaft chain sprocket using the Chain Sprocket Tensioner T40062 and torque wrench to 15 Nm in -direction of arrow- and hold.

Fig 18: Identifying Adapter T40062 On Left Camshaft Chain Sprocket

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-- Fasten bolts -1- and -2-.

-- Remove the Chain Sprocket Tensioner T40062 and Camshaft Adjustment Pins T40060.

-- Tighten the remaining bolts for the left camshaft chain sprocket.

-- Remove the Locking Pin 3242.

Fig 19: Identifying Crankshaft Holder 3242

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Fig 20: Identifying Key T40049 At Rear On Crankshaft And 2 Old Bolts For Dual-Mass Flywheel

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CAUTION:

Components could be damaged by the camshaft timing chain jump off.

Turn crankshaft only in direction of engine rotation -arrow-.

-- Turn the crankshaft two turns using the Crankshaft Key T40049 until it is just in front of "TDC".

-- Lock the crankshaft -1- from turning using the Crankshaft Holder3242 to 20 Nm.

Fig 21: Identifying Crankshaft Holder 3242

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CAUTION:

An inaccurate "TDC" setting will cause an inaccurate setting.

If the crankshaft was turned past "TDC" : Turn the crankshaft again 2 turns until it is just in front of "TDC". Then use the Crankshaft Holder3242 to keep crankshaft from turning.

-- Check whether camshafts of both cylinder heads stand in "TDC" position.

Fig 22: Checking Camshafts TDC Position

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It must be possible to secure the camshafts with the Camshaft Adjustment Pins T40060.
The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 1 (right).

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 2 (left).

Fig 23: Identifying Perpendicular Pin -Arrow- On Adjustment Pin T40060
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Correcting the valve timing

Fig 24: Identifying Bolts -Arrows-

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-- If one of the camshafts does not lock, loosen all the bolts -arrows- for that particular camshaft chain sprocket about 1 turn.

-- Mount the Camshaft Correction Tool T40061 over the bolt heads.

Fig 25: Identifying Adapter T40061 And Adjustment Pin T40060

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-- Turn the camshaft by the Camshaft Correction Tool T40061 just a little back and forth until it is possible to insert the Camshaft Adjustment Pins T40060.

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft.

-- Tighten the bolts for the camshaft chain sprocket with the Camshaft Correction Tool T40061 and the Camshaft Adjustment Pins T40060 still attached to approximately 5 Nm.

-- Remove the Camshaft Adjustment Pins T40060 and Camshaft Correction Tool T40061.

-- Tighten the camshaft chain sprocket bolts to final torque.

-- Repeat the procedure on the other cylinder bank if necessary.

-- Remove the Locking Pin 3242.

-- Check the valve timing once again, refer to CAMSHAFT TIMING CHAIN, REMOVING AND INSTALLING .

Install in reverse order of removal. Note the following:

-- Tighten the bolt for the "TDC" marking in the oil pan upper section. Refer to OIL PAN UPPER SECTION OVERVIEW .

-- Install the timing chain cover lower section. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Fill engine oil and check the oil level. Refer to Maintenance Booklet 406.