Camshaft Timing Chain, Removing From Camshafts

WARNING: This page is about a different car, the 2018 Audi TT Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Open Ring Wrench - 24mm: VAG332/11
Electronic Torque Wrench 3-60Nm: VAS6583
Crankshaft Adapter: T03003A
Locking Pin (3 pc.): T40011
Crankshaft Locking Pin: T40069
Camshaft Lock : T40264/2A
Key: T40297

Tools, Preparing

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The camshafts are secured with the : T40264/2A in "TDC".

-- If only one : T40264/2 is available, the lower bar -arrow- must be separated from the : T40264/2 .

Tools, Preparing:

Fig 1: Crankshaft Adapter T03003

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-- When only the tool Crankshaft Adapter: T03003 is available the pins must be separated so that it can be placed on the vibration damper.

Procedure

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Remove the camshaft adjustment valves. Refer to Camshaft Adjustment Valve 1 -N205- / .

-- Remove the crankcase ventilation module. Refer to CRANKCASE VENTILATION MODULE, REMOVING AND INSTALLING .

-- Turn the crankshaft in the direction of engine rotation -arrow- to "TDC" using the : T03003A .

Fig 2: Turning Crankshaft To TDC

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The notch -1- in the : T03003A is positioned vertically to the oil pan sealing surface.
The marking -2- on the vibration damper is positioned opposite the marking -3- on the sealing flange.

-- Release and remove the plug -arrow- counter-clockwise from the camshaft housing.

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The threaded holes -arrows- in the camshafts must be visible.

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TIP:

If the threaded hole is not visible, turn the crankshaft one additional turn.

-- Insert the : T40264/2A on the cylinder head and tighten to 12 Nm -arrows-, to do so turn the crankshaft slightly back and forth if necessary.

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-- Remove the locking bolt -arrow- for the "TDC" marking from the cylinder block.

Fig 3: "TDC" Locking Bolt- Marking-

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-- Install the : T40069 in the groove and tighten to 15 Nm. If necessary, move the crankshaft back and forth slightly to center the bolt.

Fig 4: Identifying Locking Pin T40069

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-- Push the chain tensioner piston for the camshaft timing chain inward all the way with a screwdriver and lock the chain tensioner with : T40011 .

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CAUTION:

Risk of damaging the camshafts.

Do not use the : T40264/2A to counterhold when loosening the camshaft adjuster bolt.

-- To counterhold, attach the : T40297 to the relevant camshaft adjuster and loosen the bolts -1-.

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-- Mark the installation position of the camshaft adjuster with paint for installation later.

CAUTION:

Risk of destroying the engine.

To prevent small parts from accidentally entering the engine through the opening in the timing chain case, seal the opening with a clean cloth.

-- Remove the bolts -1 and 2- and remove both of the camshaft adjusters.

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Installing

Fig 5: Identifying Locking Pin T40069

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Timing mechanism drive chain is installed. Refer to TIMING MECHANISM DRIVE CHAIN, REMOVING AND INSTALLING .
Secure the crankshaft with the : T40069 .

The : T40264/2A is installed and tightened to 12 Nm -arrows-.

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Replace the bolts that were tightened with an additional turn after removing them.

CAUTION:

Risk of damaging valves and piston crowns.

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

-- Mount the camshaft timing chain from the drive wheel -arrow-.

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CAUTION:

The engine could be damaged.

The camshaft adjuster must only be installed according to the following work steps.

Re-install the camshaft adjusters according to the marks applied during removal.
The groove -1 and/or 4- in the camshaft adjuster must align with the adjustment window -2 and/or 3-.

-- Position the camshaft adjuster according to the identification with the camshaft timing chain on.

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-- Loosely install the bolts -1 and 2-.

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

-- Remove the : T03006 .

-- Position the : T40297 on the camshaft adjuster of the exhaust camshaft.

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-- Position the : VAS6583 with the : VAG1332/11 on the : T40297 .

The help of a second technician is required for the following step.
Replace the bolts for the camshaft adjuster.

-- Have a second technician pretension the camshaft adjuster clockwise to 25 Nm and hold the tension.

-- Tighten the bolts as follows while the camshaft adjuster is still held under pretension.

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Step	Bolt	Tightening Specification
1a.	-1-	To the intake camshaft 60 Nm
1b.	-2-	To the exhaust camshaft 60 Nm

-- Tighten the camshaft adjuster bolts as follows:

Step	Bolt	Additional Turn
2a.	-1-	90°
2b.	-2-	90°

-- Remove the : T40297 and : T40264/2A .

-- Remove the : T40069 .

Valve Timing, Checking

Fig 6: Turning Crankshaft To TDC

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-- Using the : T03003A , turn the crankshaft two turns in the direction of engine rotation in direction of -arrow- until it is back at "TDC".

The notch -1- in the : T03003A is positioned vertically to the oil pan sealing surface.
The marking -2- on the vibration damper is positioned opposite the marking -3- on the sealing flange.

TIP:

If accidentally turned out of "TDC" the crankshaft must be rotated back two turns and set to "TDC" again.

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

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TIP:

If the threaded hole is not visible, turn the crankshaft one additional turn.

-- Install the : T40264/2A and tighten the bolts -arrows- to 12 Nm.

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-- Install the : T40069 in the groove and tighten to 15 Nm.

Fig 7: Identifying Locking Pin T40069

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The : T40069 must engage in the locating groove on the crankshaft, otherwise repeat the adjustment.

-- Remove the : T40264/2A and : T40069 .

Further installation is performed in reverse order of removal, while noting the following:

CAUTION:

Risk of damaging the valves and piston crowns after working on valvetrain.

To ensure that the vales do not make contact when starting, carefully rotate the engine at least two full revolutions.

-- Install the crankcase ventilation module. Refer to CRANKCASE VENTILATION MODULE, REMOVING AND INSTALLING .

-- Install the camshaft adjustment valves. Refer to Camshaft Adjustment Valve 1 -N205- / .

-- Install the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER, REMOVING AND INSTALLING .

After Removing or Replacing the Chain Drive Components the Adaptation Values for the Chain Length must be Adapted Again.

-- Connect the Vehicle Diagnostic Tester.

-- Select Diagnostic operating mode and Start diagnostics .

-- Select the Select individual test tab and select the following tree structure consecutively:

Drivetrain
Select the engine code and engine
01- OBD-capable systems .
01 - Engine Electronics
01 - Engine electronics, functions
01 - Chain length diagnostic adaptation

Tightening Specifications

Refer to OVERVIEW - CAMSHAFT TIMING CHAINS
Refer to OVERVIEW - CRANKSHAFT
Refer to OVERVIEW - NOISE INSULATION .