Camshaft Timing Chain, Removing And Installing: Installing

WARNING: This page is about a different car, the 2016 Audi Q5, 2015 Audi Q5, and 2014 Audi Q5. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Crankshaft Holder 3242

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Secure crankshaft -1- in "TDC" position using Locking Pin For Crankshaft T40237.

Tightening specifications:

Refer to OVERVIEW - CAMSHAFT TIMING CHAIN .
Refer to OVERVIEW - OIL PAN/OIL PUMP, OIL PAN UPPER SECTION .

NOTE:

Replace the locking bolt seal for the "TDC" marking.

Replace any bolts that were tightened with an additional turn.

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

Fig 2: Identifying Camshaft Adjustment Pins T40060 (Right Cylinder Head)

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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 3: Identifying Camshaft Adjustment Pins (Left Cylinder Head)
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-- Remove the Camshaft Adjustment Pins T40060 from both camshafts.

Fig 4: Identifying Camshaft Correction Tool T40061

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CAUTION:

Risk of damaging valves and piston crowns.

If camshafts are rotated, the 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 installing the camshaft chain sprocket on the camshaft.

-- Install the left chain sprocket with the camshaft timing chain.

Fig 5: Installing Camshaft Chain Sprocket (Left Cylinder Head)

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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.

-- Next, loosely install two bolts -1- for the camshaft chain sprocket.

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 axis of the camshaft.

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

Fig 6: Installing Right Camshaft Chain Sprocket

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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.

-- Next, loosely install two bolts -1- for the camshaft chain sprocket.

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 axis of the camshaft.

-- Secure the tensioning rail and the guide pins -2-.

Fig 7: Identifying Pin T40316

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-- Remove the Pin T40316 -1- from the securing hole, thereby releasing the right chain tensioner.

-- Loosen the bolts -2-.

Fig 8: Identifying Bolts, Balance Shaft And Diesel Injection Pump Locking Pin 3359

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-- Stop the balance shaft -3- with the Diesel Injection Pump Locking Pin 3359 as shown in the illustration.

NOTE:

Remove the bolts if necessary and move the balance shaft into position.

-- Loosely install the bolts -2-.

It must still be possible to rotate the chain sprocket -1- on the balance shaft and it must not tip.

-- Have a 2nd technician tension the right camshaft chain sprocket clockwise -arrow- with the Chain Sprocket Tensioner T40062 and the torque wrench to 20 Nm and maintain the pretension.

Fig 9: Identifying Bolts And Chain Sprocket Tensioner T40062

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-- Tighten the bolts -1 and 2- to the right camshaft chain sprocket.

-- Continue to maintain the pretension and tighten the bolts -1- to the right camshaft chain sprocket.

Fig 10: Installing Camshaft Chain Sprocket (Left Cylinder Head)

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-- Tighten the bolts -2- for the chain sprocket -1- for the balance shaft -3-.

Fig 11: Identifying Bolts, Balance Shaft And Diesel Injection Pump Locking Pin 3359

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-- Remove the Diesel Injection Pump Locking Pin 3359, Chain Sprocket Tensioner T40062 and Camshaft Adjustment Pins T40060.

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

-- Remove the Crankshaft Holder 3242.

Fig 12: Crankshaft Holder 3242

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Checking the Valve Timing

-- Remove the Crankshaft Holder 3242.

CAUTION:

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

Only rotate the crankshaft in the direction of engine rotation.

-- Turn the crankshaft two turn until the crankshaft is just in front of "TDC".

Fig 13: Identifying Crankshaft Key Tool T40049

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-- Lock the crankshaft -1- from turning using the Crankshaft Key 3242 to 20 Nm.

Fig 14: 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 Holder 3242 to keep crankshaft from turning.

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

Fig 15: Installing Camshaft Adjustment Pins 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 16: Installing Camshaft Adjustment Pins T40060 (Left Cylinder Head)
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Correcting the Valve Timing

Fig 17: Camshaft Sprocket Bolts (Left Cylinder Head)

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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 18: Identifying Camshaft Correction Tool T40061

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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 axis of the camshaft.

Fig 19: Installing Camshaft Adjustment Pins T40060 (Left Cylinder Head)
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-- 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 the 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 Crankshaft Holder 3242.

-- Check the valve timing once again, refer to INSTALLING - "Checking the Valve Timing " (See Fig 13).

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

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