Camshaft timing chains, removing from camshafts

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

For the removal of the cylinder head or camshafts, it is sufficient to remove camshaft timing chains only from the camshafts. Chains remain on the engine; only the top covers at left and right are removed.
Even if work is performed only on one of the cylinder heads, the procedure described must be followed, since then the valve timing at both cylinder heads must be adjusted.

Fig 1: Identifying Special Tools - Camshaft Timing Chains, Removing From Camshafts

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Special tools, testers and auxiliary items required

Crankshaft Holder 3242
Trim removal wedge 3409 (2x)
Old oil collecting and extracting device V.A.G 1782
Multi-point socket T10035

Camshaft locator T40046 (qty. 2)
Setting gauge T40047

Fig 2: Identifying Old Oil Collecting And Extracting Device V.A.G 1782

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Old oil collecting and extracting device V.A.G 1782

Drill bit 3.3 mm dia. (2x)

Work procedure

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Place old oil collecting and extracting device V.A.G 1782 under engine and drain engine oil.
Remove engine: Vehicles with manual transmission → Engine (vehicles with manual transmission) , vehicles with automatic transmission → Engine (vehicles with automatic transmission), removing .
Leave engine with transmission installed on scissor lift platform VAS 6131 A.

Fig 3: Disconnecting Electrical Connection At Throttle Valve Control Module J338 & Crankcase Ventilation Hose At Intake Pipe

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Disconnect electrical connection - 1 - at throttle valve control module J338.
Disconnect crankcase ventilation hose - 3 - at intake pipe.

NOTE:

Disregard item - 2 -.

Fig 4: Remove Electrical Harness Connectors Toward Front From Brackets On Intake Line

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Remove electrical harness connectors - 1 - , - 2 - , - 5 - and - 6 - toward front from brackets on intake line.
Disconnect electrical connectors - 3 - and - 4 -.

Fig 5: Disconnecting Vacuum Hose At T-Piece

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Disconnect vacuum hose - arrow - at T-piece.

Fig 6: Identifying Connector Strips At Fuel Injectors, Vacuum Line On Fuel Pressure Regulator & Retaining Bolts For Fuel Rail Line

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Disconnect connector strips - 1 - and - 5 - at fuel injectors.
For vehicles with fuel return line, disconnect vacuum line - 4 - on fuel pressure regulator.
Remove retaining bolts - 2 - and - 3 - for fuel rail line.
Remove fuel rail line together with fuel injectors from intake manifold uniformly upward.

NOTE:

Carefully protect the removed fuel injectors from contamination.

Fig 7: Removing Left/Rear Engine Lifting Eye

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Remove left rear engine lifting eye - arrows -.

Fig 8: Removing Intake Manifold Bolts

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Remove intake manifold bolts - arrows - and remove it.

NOTE:

Plug intake ports of the cylinder head with clean rags.

Fig 9: Removing Cap For Oil Filter Housing

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Remove cap - arrow - for oil filter housing.
Remove oil filter element.
Extract engine oil using old oil collecting and extracting device V.A.G 1782 from oil filter housing.

NOTE:

Place a rag around oil filter housing to catch escaping engine oil.

Fig 10: Removing Bolts & Oil Filter Housing

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Remove bolts - arrows -.
Remove oil filter housing.

Fig 11: Removing Bolts & Return Line From Power-Steering Pump

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Remove bolts - 1 - and - 2 -.
Place old oil collecting and extracting device V.A.G 1782 underneath.
Remove return line from power-steering pump - arrow -.

Fig 12: Removing Bolt From Oil Dipstick Guide Tube At Cylinder Head

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Remove guide pipe bolt - arrow - for oil dipstick at cylinder head, pull up and remove.

Fig 13: Removing Bolts, Locating Hose Clamps And Removing Left Coolant Pipe From Coolant Hoses

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Remove bolts - 1 - and - 2 -.
Loosen hose clamps - arrows - and remove left coolant pipe from coolant hoses.

Fig 14: Removing Bolts, Locating Hose Clamps And Removing Right Coolant Pipe From Coolant Hoses

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Remove bolts - 1 - and - 2 -.
Loosen hose clamps - arrows - and remove right coolant pipe from coolant hoses.

Fig 15: Disconnecting Electrical Harness Connector On Engine Coolant Temperature (ECT) Gauge Sensor G2/G62

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Disconnect electrical harness connector - 2 - on Engine Coolant Temperature (ECT) Gauge Sensor G2/G62.
Remove nut - 1 - and remove electrical wiring harness at rear coolant pipe.

Fig 16: Removing Bolts & Rear Coolant Pipe

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Remove bolts - 2 to 5 -.
Remove rear coolant pipe.

NOTE:

Ignore - 1 - and - 6 -.

Fig 17: Removing Mounting Bolts Of Combination Valves For Secondary Air Injection (AIR) System

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Remove mounting bolts - 1 to 4 - of combination valves for Secondary Air Injection (AIR) system.

Fig 18: Removing Nuts And Left Exhaust Manifold

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Remove nuts - 1 to 12 - and remove left exhaust manifold.

Fig 19: Removing Left Heat Shield

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Remove left heat shield - arrows -.

Fig 20: Removing Nuts And Right Exhaust Manifold

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Remove nuts - 1 to 12 - and remove right exhaust manifold.

Fig 21: Removing Right Heat Shield

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Remove right heat shield - arrows -.

Fig 22: Removing Bolts On Left Cylinder Head, Disconnecting Electrical Harness Connectors & Removing Ignition Coils

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Remove bolts - 5 - and - 6 - on left cylinder head.
Disconnect electrical harness connectors - 1 to 4 -.
Remove ignition coils - arrows -.

NOTE:

Extractor T40039 can be used for removal.

Fig 23: Disconnecting Hose Of Crankshaft Housing Ventilation & Removing Left Cylinder Head Cover Bolts In Sequence

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Disconnect hose of crankshaft housing ventilation - arrow -.
Remove left cylinder head cover bolts in sequence - 15 to 1 -.
Remove cylinder head cover.

Fig 24: Removing Bolts On Right Cylinder Head, Disconnecting Electrical Harness Connectors & Removing Ignition Coils

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Remove bolts - 5 - and - 6 - on right cylinder head.
Disconnect electrical harness connectors - 1 to 4 -.
Remove ignition coils - arrows -.

NOTE:

Extractor T40039 can be used for removal.

Fig 25: Disconnecting Hose Of Crankshaft Housing Ventilation & Removing Right Cylinder Head Cover Screws In Sequence

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Disconnect hose of crankshaft housing ventilation - arrow -.
Remove right cylinder head cover bolts in sequence - 15 to 1 -.
Remove cylinder head cover.

Fig 26: Disconnecting Electrical Harness Connector For Camshaft Position (CMP) Sensor 2 G163 On Left Cylinder Head

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Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor 2 G163 on left cylinder head.

Fig 27: Pressing Sealing Ring For Crankshaft At Rear Out Of Cover

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Disconnect electrical harness connector - arrow - for Camshaft Position (CMP) Sensor G40 on right cylinder head.

Fig 28: Removing Ground (GND) Cable On Right Cylinder Head

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Remove Ground (GND) wire on right cylinder head - arrow -.
Set wiring harness aside.

Fig 29: Removing/Installing Bolts And Left Timing Chain Cover

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Remove bolts - 1 to 6 - and remove left timing chain cover.

Fig 30: Removing Bolts And Right Timing Chain Cover

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Remove bolts - 1 to 6 - and remove right timing chain cover.

Fig 31: Rotating Crankshaft To TDC Ignition Timing

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Rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.

Fig 32: Identifying Slits At Front In Camshafts Stand Parallel At Same Height With Upper Edge Of Cylinder Head

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Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

Fig 33: Removing/Inserting Camshaft Locator T40046 From/Into Camshafts Of Right Cylinder Head

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Rotate camshafts at hex head slightly back and forth if necessary so that camshaft locator T40046 can be inserted.
If camshaft locator T40046 cannot be inserted, rotate crankshaft 1 rotation (360 °) further.
Remove camshaft locator T40046 again.
Remove drain plug from upper section of oil pan.

Fig 34: Removing/Installing Crankshaft Holder 3242 Into Hole

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Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

Fig 35: Pushing Glide Track Of Chain Tensioner For Left Timing Chain

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Push glide track of chain tensioner for left timing chain in direction of - arrow - and pull off chain tensioner using a drill bit - 1 - 3.3 mm in dia.

NOTE:

In the following illustration, the timing mechanism is depicted with covers completely removed.

Fig 36: Removing Bolts For Camshaft Chain Sprocket Or Camshaft Adjuster Using Multipoint Socket T10035

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Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
Remove camshaft chain sprocket and camshaft adjuster.

NOTE:

Camshaft timing chain remains on engine.
Also, if only one of the two cylinder heads is removed, bolts for camshaft gears must be loosened at both cylinder heads.

Fig 37: Pushing Glide Track Of Chain Tensioner For Right Timing Chain

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Push glide track of chain tensioner for right timing chain in direction of - arrow - and pull off chain tensioner using a drill bit - 1 - 3.3 mm in dia.

Fig 38: Removing Bolts For Camshaft Chain Sprocket Or Camshaft Adjuster Using Multipoint Socket T10035

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Remove bolts - 1 - and - 2 - for camshaft chain sprocket or camshaft adjuster using multipoint socket T10035.
Remove camshaft chain sprocket and camshaft adjuster.

NOTE:

Camshaft timing chain remains on engine.
Also, if only one of the two cylinder heads is removed, bolts for camshaft gears must be loosened at both cylinder heads.

Installing

Secure crankshaft in TDC position using Crankshaft Holder 3242.

NOTE:

Always replace bolts that are tightened to torque as well as O-rings and gaskets.
When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged.
During installation, all cable ties must be re-installed at the same location.

Fig 39: Rotating Inner Part And Outer Part Of Both Camshaft Adjusters Against Each Other Up To Lock Position

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Rotate inner part and outer part of both camshaft adjusters against each other up to lock position - arrows -.

Inner part and outer part must not be able to be against each other in lock position (slight play can still be felt).

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

Fig 40: Identifying Slits At Front In Camshafts Stand Parallel At Same Height With Upper Edge Of Cylinder Head

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Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

Fig 41: Removing/Installing Camshaft Locator T40046

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Insert camshaft locator T40046 into camshafts of left cylinder head, to do so rotate camshafts back and forth at hex head if necessary.

Fig 42: Removing/Inserting Camshaft Locator T40046 From/Into Camshafts Of Right Cylinder Head

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Insert camshaft locator T40046 into camshafts of right cylinder head, to do so rotate camshafts back and forth at hex head if necessary.
Replace all four camshaft bolts.
Replace diamond disc between camshaft and left cylinder head camshaft adjuster.
Assemble left timing chain with chain sprocket and camshaft adjuster.

Fig 43: Removing Bolts For Camshaft Chain Sprocket Or Camshaft Adjuster Using Multipoint Socket T10035

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Loosely install bolts - 1 - and - 2 -.

Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip.

Replace diamond disc between camshafts and right cylinder head camshaft adjuster.
Assemble right timing chain with chain sprocket and camshaft adjuster.

Fig 44: Removing/Installing Bolts For Camshaft Chain Sprocket Or Camshaft Adjuster Using Multipoint Socket T10035

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Loosely install bolts - 1 - and - 2 -.

Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip

Fig 45: Removing/Installing Crankshaft Holder 3242 Into Hole

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Remove Crankshaft Holder 3242.

Fig 46: Rotating Crankshaft 30 ° In Opposite Direction Of Engine Rotation

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Rotate crankshaft 30 ° in opposite direction of engine rotation - arrow -.
Pull drill out of alignment hole, which loosens left chain tensioner.

Fig 47: Inserting Trim Removal Wedge 3409

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Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with trim removal wedge 3409.

Lightly pressing in an extra 0.5 mm is permitted.

Pull drill out of alignment hole, which loosens right chain tensioner.

Fig 48: Insert Trim Removal Wedge 3409

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Insert trim removal wedge 3409 as shown in illustration and bring chain tensioner into contact with trim removal wedge 3409.

Lightly pressing in an extra 0.5 mm is permitted.

Fig 49: Rotating Crankshaft To TDC Ignition Timing

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Rotate crankshaft in direction of engine rotation - arrow - to TDC ignition timing.

NOTE:

If rotated unintentionally beyond TDC, turn back crankshaft again approx. 30 ° and set to TDC again.

Fig 50: Removing/Installing Crankshaft Holder 3242 Into Hole

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Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

Fig 51: Locating Camshaft Bolt On Exhaust Camshaft Of Left Cylinder Head

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Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to initial tightening torque.

Torque specification: 40 Nm.

Fig 52: Securing Hall Sensor Wheel On Camshaft Adjuster Of Intake Camshaft Of Left Cylinder Head Using Setting Gauge T40047

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Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
Place setting gauge on bolt - 1 -.
Tighten camshaft bolt - 2 - on intake camshaft to initial tightening torque.

Torque specification: 40 Nm.

Fig 53: Securing Hall Sensor Wheel On Camshaft Adjuster Of Intake Camshaft Of Right Cylinder Head Using Setting Gauge T40047

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Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
Place setting gauge on bolt - 2 -.
Tighten camshaft bolt - 1 - on intake camshaft to initial tightening torque.

Torque specification: 40 Nm.

Remove setting gauge.

Fig 54: Locating Camshaft Bolt On Exhaust Camshaft Of Right Cylinder Head

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Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to initial tightening torque.

Torque specification: 40 Nm.

NOTE:

Camshaft locators must not be used as counter holder for final tightening of camshaft bolts.

Fig 55: Removing/Installing Camshaft Locator T40046

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Remove camshaft locators T40046 on both cylinder heads.

Fig 56: Locating Camshaft Bolt On Exhaust Camshaft Of Left Cylinder Head

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Tighten camshaft bolt - 1 - on exhaust camshaft of left cylinder head to final tightening torque.

Torque specification: 100 Nm plus an additional (¹ /₄ turn (90 °).

Fig 57: Securing Hall Sensor Wheel On Camshaft Adjuster Of Intake Camshaft Of Left Cylinder Head Using Setting Gauge T40047

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Secure Hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using setting gauge T40047.
Place locator on bolt - 1 -.
Tighten camshaft bolt - 2 - on intake camshaft to final tightening torque.

Torque specification: 100 Nm plus an additional (¹ /₄ turn (90 °).

Fig 58: Securing Hall Sensor Wheel On Camshaft Adjuster Of Intake Camshaft Of Right Cylinder Head Using Setting Gauge T40047

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Secure Hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using setting gauge T40047.
Place setting gauge T40047 on bolt - 2 -.
Tighten camshaft bolt - 1 - on intake camshaft to final tightening torque.

Torque specification: 100 Nm plus an additional (¹ /₄ turn (90 °).

Remove setting gauge T40047.

Fig 59: Locating Camshaft Bolt On Exhaust Camshaft Of Right Cylinder Head

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Tighten camshaft bolt - 2 - on exhaust camshaft of right cylinder head to final tightening torque.

Torque specification: 100 Nm plus an additional (¹ /₄ turn (90 °).

Fig 60: Removing/Installing Crankshaft Holder 3242 Into Hole

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Remove Crankshaft Holder 3242.

Fig 61: Rotating Crankshaft To TDC Ignition Timing

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Turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at TDC again.

Fig 62: Identifying Slits At Front In Camshafts Stand Parallel At Same Height With Upper Edge Of Cylinder Head

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Slits - arrows - at front in camshafts must stand parallel at same height with upper edge of cylinder head.

Fig 63: Removing/Installing Crankshaft Holder 3242 Into Hole

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Install Crankshaft Holder 3242 into hole (20 Nm), if necessary rotate crankshaft very slightly back and forth to completely center holder.

Fig 64: Removing/Installing Camshaft Locator T40046

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Insert camshaft locator T40046 into camshafts of left cylinder head.

Fig 65: Removing/Inserting Camshaft Locator T40046 From/Into Camshafts Of Right Cylinder Head

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Insert camshaft locator T40046 into camshafts of right cylinder head.

If camshaft locators cannot be inserted:

Repeat adjustment.
Pull out trim removal wedge 3409.
Remove camshaft locator T40046 on both cylinder heads.
Remove Crankshaft Holder 3242.

Install sealing plug of TDC marking with new sealing ring into upper section of oil pan.

The rest of installation is in reverse order of removal, note the following:

Install covers for timing chains Installing .
Install engine: Vehicles with manual transmission → Engine (vehicles with manual transmission), installing , vehicles with automatic transmission → Engine (vehicles with automatic transmission), installing .
Add engine oil and check oil level → Oil level, checking .

Torque specifications

Component	Nm
Camshaft bolts	100 plus an additional 90 ° * See note
Sealing plug in upper section of oil pan	35
Oil drain plug	50

* 90 ° corresponds to one quarter rotation.

*Replace bolts.