Timing Mechanism Drive Chain And Camshaft Timing Chain

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Camshaft Bar T10068 A
Counter-Holder Tool T10069
Sealant.

Removing

-- Removing engine. Refer to ENGINE, REMOVING .

-- To separate engine and transmission: Vehicles with manual transmission ENGINE AND MANUAL TRANSMISSION, SEPARATING , vehicles with direct shift automatic transmission (DSG) ENGINE AND DSG TRANSMISSION, SEPARATING .

-- Remove dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

-- Remove intake manifold. Refer to Removal and Installation .

-- Remove coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

Vehicles with engine code BUB:

-- Remove the hose -2- from the secondary air injection (AIR) combination valve.

Fig 1: Identifying Secondary Air Injection (Air) Combination Valve Component Location

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NOTE:

Ignore -1-.

Vehicles with engine code CBRA:

-- Disconnect the hose -1- and the vacuum hose -2- from the left Secondary Air Injection (AIR) combination valve.

Fig 2: Identifying Hose -1- And Vacuum Hose -2- From Left AIR Combination Valve

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NOTE:

Ignore -3- and -arrows-.

All Vehicles

-- Mark and disconnect electrical connectors:

Fig 3: Marking And Removing Connectors

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Camshaft adjustment valve 1 (exhaust) -N318-
Camshaft adjustment valve 1 -N205-
Camshaft position sensor -G40-
Camshaft position (CMP) sensor 2 -G163-

-- Remove Ground (GND) wire -5-.

-- Disconnect coolant hose -6-.

-- Remove electrical wiring bracket -arrows-.

-- Place bracket with electrical wiring toward front.

-- Remove cylinder head cover. Refer to CYLINDER HEAD COVER .

-- Remove the oil pan. Refer to OIL PAN .

-- Adjust crankshaft at vibration damper bolt in direction of engine rotation to "TDC" marking -arrow-.

Fig 4: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

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-- Cams -A- of cylinder 1 must face each other.

Fig 5: Camshaft Lobes For Cylinder Facing Each Other

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-- At the same time, T10068 A must engage in both shaft grooves. Turn crankshaft 1 additional turn if necessary.

Fig 6: Identifying Camshaft Bar T10068 A Engage In Shaft Grooves

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-- Remove camshaft timing chain tensioner -arrow-.

Fig 7: Camshaft Timing Chain Tensioner

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-- Remove the bolts -1, 2 and 3-.

Fig 8: Identifying Cylinder Head Cover Bolts

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CAUTION:

The cylinder head seal could be damaged.

Remove upper timing chain cover horizontally from cylinder head.

-- Remove lower timing chain cover bolts -arrow-.

Fig 9: Identifying Crankshaft Seal On Timing Chain Side Of Cover

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CAUTION:

The cylinder head seal could be damaged.

Remove timing chain lower cover horizontally from cylinder block.

-- Press crankshaft sealing ring out of timing chain lower cover.

-- Mark timing chain running direction with arrows using paint -arrows- for reinstallation.

Fig 10: Identifying Markings On Roller Chains

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CAUTION:

Risk of damaging timing chain.

Do not mark chain with punch, notch or something similar.

-- Remove bolts -arrows- and remove guide rail -1-.

Fig 11: Locating Guide Rail & Bolts

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-- Remove camshaft adjuster timing chain from intermediate shaft chain sprocket.

-- Carefully remove camshaft timing chain behind cylinder head seal rib.

-- Loosen chain sprocket bolt -arrow- approximately 1 turn.

Fig 12: Chain Sprocket Bolt

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-- Counter hold with T10069 at vibration damper bolt.

Fig 13: Counter-Holder T10069 To Hold Vibration Damper

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-- Remove timing mechanism drive chain tensioner -arrows-.

Fig 14: Chain Tensioner Bolts

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-- Remove bolt -arrow- and remove drive chain together with chain sprockets from intermediate shaft.

Fig 15: Chain Sprocket Bolt

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Installing

Tightening specifications, refer to TIMING CHAIN COVERS ASSEMBLY OVERVIEW , TIMING CHAIN COMPONENT OVERVIEW .

-- When reinstalling a used timing mechanism drive chain, note running direction marking -lower arrow-.

Fig 16: Identifying Markings On Roller Chains

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-- Install drive chain together with large chain sprocket on intermediate shaft.

Fig 17: Identifying Large Sprocket Installed Into Timing Chain With Tab Aligned To Mark On Cylinder Block

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Installation only possible in one position.

-- If large chain sprocket cannot be installed, rotate intermediate shaft slightly.

-- Check if crankshaft is in "TDC" position:

Milled drive chain sprocket tooth must align with bearing joint -arrow A-.
Tab on intermediate shaft sprocket must align with notch -arrow B- on intermediate shaft thrust washer.

-- Install small chain sprocket on intermediate shaft.

Fig 18: Chain Sprocket Bolt

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Installation only possible in one position.

-- Replace the chain sprocket bolt for the intermediate shaft.

-- Tighten chain sprocket bolt -arrow- by hand.

-- Release locking splines in chain tensioner with small screwdriver -arrow-.

Fig 19: Identifying Small Screwdriver To Release Locking Splines Of Chain Tensioner

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-- Press tensioning rail against chain tensioner and tighten chain tensioner in this position -arrows-.

Fig 20: Chain Tensioner Bolts

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-- Tighten chain sprocket bolt -arrow-.

Fig 21: Chain Sprocket Bolt

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-- Counter hold with T10069 at vibration damper bolt.

Fig 22: Counter-Holder T10069 To Hold Vibration Damper

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-- Place the timing chain on the camshaft adjuster in such a way that the 2 individual copper color chain sprockets -CA- align with the markings on the camshaft adjuster. It is possible that the intake camshaft adjust will have to be rotated slightly.

Fig 23: Identifying Alignment Of Marks To Copper Colored Chain Links

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-- Mount the timing chain on the small chain sprocket. The marking -B- must align with the center copper color chain link -A-.

-- Insert guide track -1- and tighten bolts -arrows-.

Fig 24: Locating Guide Rail & Bolts

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-- Remove T10068 A.

CAUTION:

Risk of timing chain jumping off.

If the crankshaft is rotated, forcefully press camshaft tensioning rail by hand (instead of with chain tensioner) against camshaft adjuster timing chain -arrow-.

Fig 25: Identifying Vibration Damper And Counter-Holder Tool T10069

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-- Rotate crankshaft 2 revolutions in direction of engine rotation at vibration damper bolt and place at "TDC" marking -arrow-.

Fig 26: Identifying Crankshaft At Vibration Damper Securing Bolt In Engine At TDC Cyl. 1

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-- Cams -A- of cylinder 1 must face each other.

Fig 27: Camshaft Lobes For Cylinder Facing Each Other

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-- At the same time, the T10068 A must engage in both shaft grooves.

Fig 28: Identifying Camshaft Bar T10068 A Engage In Shaft Grooves

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NOTE:

Marked links now take on an undefined position.

If the camshaft bar cannot be inserted:

-- Repeat valve timing adjustment.

-- Clean sealant residue from 3 mm bores -arrows- in cylinder head seal.

Fig 29: Locating 3 mm Holes In Cylinder Head Gasket

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NOTE:

With cylinder head installed, holes in cylinder head seal are only half visible.

-- Check whether timing chain lower cover guide pins are inserted in cylinder block.

-- Lightly coat clean sealing surfaces -shaded- on timing chain lower cover with sealant.

Fig 30: Identifying Sealing Surfaces

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NOTE:

Timing chain lower cover must be installed with 5 minutes of applying sealant.

-- Remove lower timing chain cover bolts -arrow-.

Fig 31: Identifying Crankshaft Seal On Timing Chain Side Of Cover

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-- Fill 3 mm bores -arrows- in cylinder head seal with sealant.

Fig 32: Locating 3 mm Holes In Cylinder Head Gasket

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NOTE:

With cylinder head installed, holes in cylinder head seal are only half visible.

-- Replace timing chain upper cover sealing ring. Refer to TIMING CHAIN UPPER COVER SEAL .

-- Check whether fitting sleeves -2- and -3- are inserted in upper timing chain cover.

Fig 33: Checking Dowel Sleeves And Are Inserted In Upper Cover For Camshaft Timing Chain

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-- Insert new sealing ring -1- and new seal -4-.

-- Lightly coat clean sealing surface -shaded- on timing chain upper cover with sealant.

-- Coat sealing surface below cylinder head seal with some sealant. Do not bend cylinder head seal.

NOTE:

Timing chain upper cover must be installed with 5 minutes of applying sealant.

-- Position upper timing chain cover and tighten. Refer to Figure.

Fig 34: Identifying Cylinder Head Cover Bolts

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-- Install camshaft timing chain tensioner -arrow-.

Fig 35: Camshaft Timing Chain Tensioner

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-- Rotate crankshaft 2 revolutions in direction of engine rotation at vibration damper bolt and place at "TDC" marking.

-- Check timing again.

-- Install crankshaft sealing ring. Refer to CRANKSHAFT SEAL, REPLACING .

-- Install cylinder head cover. Refer to CYLINDER HEAD COVER

-- Install intake manifold. Refer to Removal and Installation .

-- Install coolant thermostat housing. Refer to COOLANT THERMOSTAT HOUSING .

-- Install oil pan OIL PAN => Installing .

-- Install dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

-- Install engine. Refer to ENGINE, INSTALLING .

-- Fill engine oil and check oil level. Refer to OIL LEVEL, CHECKING .