Detaching timing chains from camshaft, removing and installing chain tensioner: Installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

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.
Drive chain for timing mechanism installed → Drive chain for timing mechanism, removing and installing .

Fig 1: Installing Crankshaft Holder T40069 Into Hole

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Secure crankshaft in TDC position using crankshaft holder T40069.

Fig 2: Mounting Camshaft Locating Tool T40070 To Both Cylinder Heads And Locating Bolts

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Camshaft locating tool T40070 mounted on both cylinder heads and tightened to 20 Nm.

Fig 3: Fully Relieving Tension Of Guide Rail For Left/Right Camshaft Timing Chain Tensioner

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Fully relieve tension of guide rail for left and right camshaft timing chain tensioner - arrow -.

The piston of tensioning element - 1 - must be driven out completely, thereby releasing retainer - for this chain tensioner must be removed.

NOTE:

If the tensioning element is to be removed from the chain tensioner, observe the installed position: Hole in housing floor faces toward chain tensioner, piston faces toward tensioning rail.

Fig 4: Pressing Guide Rail Of Left/Right Camshaft Timing Chain Inward Up To Stop And Secure Chain Tensioner With Securing Pin T40071

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Press guide rail of left and right camshaft timing chain inward - arrow - up to stop and secure chain tensioner with securing pin T40071.

Fig 5: Cleaning Oil Strainer In Both Chain Tensioners & Placing New Gasket Onto Rear Of Chain Tensioner

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Clean oil strainer - 3 - in both chain tensioners, if necessary.
Place a new gasket - 2 - onto rear of chain tensioner - 1 -.
Set chain tensioner in place on left cylinder head and install camshaft timing chain, as shown in the illustration.

Fig 6: Locating Bolts & Replacing Camshaft Bolts

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Tighten bolts - 1 - and - 2 -.
Replace camshaft bolts.

Fig 7: Locating Camshaft Bolts On Left Cylinder Head

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Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 - and - 2 -.

Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

Remove Locking Pin T40071.
Set chain tensioner in place on right cylinder head and install camshaft timing chain, as shown in the illustration.

Fig 8: Locating Bolts & Replacing Camshaft Bolts

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Tighten bolts - 1 - and - 2 -.
Replace camshaft bolts.

Fig 9: Removing Bolts For Camshaft Adjuster Using Multipoint Socket T10035

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Place camshaft timing chain onto drive sprocket and onto camshaft adjusters and loosely thread in bolts - 1 - and - 2 -.

Both camshaft adjusters must be able to still be rotated on camshaft and must not tip.

Remove Locking Pin T40071.

Fig 10: Setting Counter-Holder T10172 With Pin T10172/2 In Place On Camshaft Adjuster Of Left Intake Camshaft

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Set counter-holder T10172 with pin T10172/2 in place on camshaft adjuster of left intake camshaft.
Hold camshaft timing chain pre-tensioned by pressing on counter-holder in direction of - arrow -.
Simultaneously, pre-torque camshaft bolt using multipoint socket T10035 and torque wrench.

Torque specification: 40 Nm.

Continue holding pretension on intake camshaft and pre-torque bolt - 1 - on exhaust camshaft.

Torque specification: 40 Nm.

Fig 11: Locating Camshaft Bolts On Left Cylinder Head

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Tighten camshaft bolts - 1 - and - 2 - on left cylinder head to final torque specification.

Torque specification: 80 Nm plus an additional 90 ° ( ¹ /₄ turn).

Fig 12: Setting Counter-Holder T10172 With Pin T10172/2 In Place On Camshaft Adjuster Of Right Exhaust Camshaft

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Set counter-holder T10172 with pin T10172/2 in place on camshaft adjuster of right exhaust camshaft.
Hold camshaft timing chain pre-tensioned by pressing on counter-holder in direction of - arrow -.
Simultaneously, pre-torque camshaft bolt using multipoint socket T10035 and torque wrench.

Torque specification: 40 Nm.

Continue holding pretension on exhaust camshaft and pre-torque bolt - 1 - on intake camshaft.

Torque specification: 40 Nm.

Fig 13: Locating Camshaft Bolts On Right Cylinder Head

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Tighten camshaft bolts - 1 - and - 2 - on right cylinder head to final torque specification.

Torque specification: 80 Nm plus an additional 90 ° ( ¹ /₄ turn).

Fig 14: Mounting Camshaft Locating Tool T40070 To Both Cylinder Heads And Locating Bolts

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Remove camshaft locators T40070 on both cylinder heads.

Fig 15: Removing/Installing Crankshaft Holder T40069

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Remove crankshaft holder T40069.

Fig 16: Locating Torque Converter Bolts Using Adapter T40058

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Using key T40058 turn crankshaft two complete rotations in direction of engine rotation - arrow - until crankshaft stands at TDC again.

NOTE:

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

Fig 17: Identifying Threaded Holes In Camshafts Must Face Upward

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The threaded holes - arrows - in camshafts must face upward.

Fig 18: Mounting Camshaft Locating Tool T40070 To Both Cylinder Heads And Locating Bolts

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Mount camshaft locating tools T40070 to both cylinder heads and tighten bolts - arrows - to 20 Nm.

The camshaft locating tool T40070 is correctly positioned when holes for cylinder head bolts remain free.

Fig 19: Installing Crankshaft Holder T40069 Into Hole

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Install crankshaft holder T40069 directly into hole.

The crankshaft holder T40069 must engage in locating hole of crankshaft - 1 - , otherwise repeat adjustment.

Remove camshaft locating tools on both cylinder heads.
Remove crankshaft holder.

Fig 20: Removing/Installing Sealing Plug From Cylinder Block

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Install sealing plug - arrow - of TDC marking with new seal into cylinder block.

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

Install stabilizer bar → 40 - FRONT SUSPENSION .
Install left and right timing chain covers → Left and right timing chain covers, removing and installing .
Install cylinder head cover: Left → Left cylinder head cover, removing and installing , right → Right cylinder head cover, removing and installing .