Camshaft Timing Chain, Removing And Installing, Engine With Two Camshaft Adjusters: Installing

Fig 1: Check The Crankshaft @ TDC

Courtesy of AUDI OF AMERICA, LLC

-- Check the crankshaft at TDC. The flat area on the crankshaft -arrow- must be horizontal.

-- Draw the markings on the cylinder block -1- with a waterproof marker.

-- Draw a marking -2- on the three stage chain sprocket tooth -1- with a waterproof marker.

Fig 2: Draw Marking On Three Stage Chain Sprocket Tooth

Courtesy of AUDI OF AMERICA, LLC

-- Turn the intermediate sprocket and balance shaft to the marks -arrow-, but do not loosen the bolt -1-.

Fig 3: Identifying Intermediate Shaft Sprocket

Courtesy of AUDI OF AMERICA, LLC

The painted links of the chain must be positioned on the markings on the chain sprockets.

Fig 4: Identifying Chain Sprockets
Courtesy of AUDI OF AMERICA, LLC
Ignore the position of any additional painted chain links that may also be present.

-- Lay the balance shaft drive chain, and position the painted links -arrows- with the markings on the chain sprockets.

-- Install the guide rail -1- and tighten the bolts -arrows-.

Fig 5: Identifying Guide Rail And Tighten Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Engage the camshaft timing chain with the painted links -arrows- on the camshaft pins.

Fig 6: Camshaft Timing Chain And Camshaft Sprocket

Courtesy of AUDI OF AMERICA, LLC

-- Lay the oil pump drive timing chain onto the three stage chain sprocket.

Fig 7: Identifying Three Stage Chain Sprocket

Courtesy of AUDI OF AMERICA, LLC

-- Swing the three stage chain sprocket in the direction of -arrow- toward the engine and secure to the crankshaft. The marks -arrows- must be positioned opposite each other.

-- Install the Assembly Tool - Tensioning Pins: T10531/2 in the crankshaft and tighten hand-tight.

Fig 8: Identifying Assembly Tool - Turning Over Tool T10531/3

Courtesy of AUDI OF AMERICA, LLC

-- Install the Assembly Tool - Turning Over Tool: T10531/3 . Tighten the Assembly Tool - Knurled Nut: T10531/4 hand-tight. Using a 32 mm open end wrench move the Assembly Tool - Turning Over Tool back and forth slightly while doing this tighten the Assembly Tool - Knurled Nut until the chain sprocket is seated securely on the crankshaft splines. Now tighten the adjusting bolt -A-.

-- Position the painted chain link in the balance shaft drive chain -arrow- at the mark on the three stage chain sprocket. Install the tensioning rail -1- and the guide rail -2-. Tighten the bolts -3-.

Fig 9: Identifying Painted Chain Link In Balance Shaft Drive Chain

Courtesy of AUDI OF AMERICA, LLC

-- Install the chain tensioner -1-.

Fig 10: Chain Tensioner And Balance Shaft Timing Chain

Courtesy of AUDI OF AMERICA, LLC

-- Check the adjustment again. The painted chain links -arrows- must line up with the markings on the chain sprockets.

Fig 11: Identifying Painted Chain Links

Courtesy of AUDI OF AMERICA, LLC

-- Place the camshaft timing chain on the intake camshaft, exhaust camshaft and the crankshaft. Position the painted chain links -arrows- on the marks on the chain sprockets.

Fig 12: Camshaft Timing Chain And Intake Camshaft

Courtesy of AUDI OF AMERICA, LLC

-- Install the guide rail -2- and tighten the bolts -1-.

Fig 13: Removing Glide Rail

Courtesy of AUDI OF AMERICA, LLC

-- Install the upper guide rail -1-.

Fig 14: Removing Guide Rail

Courtesy of AUDI OF AMERICA, LLC

The help of a second technician is necessary for the following step.

Courtesy of AUDI OF AMERICA, LLC

-- Use the Adapter: T40266 to turn the exhaust camshaft slightly in the direction of -arrow A- and push the Camshaft Lock: T40271/1 out of the chain sprocket splines in the direction of -arrow B-.

-- Release the camshaft in the direction of -arrow C-, until the timing chain touches the guide rail -1-. Hold the camshaft in this position, install the tensioning rail -2- and tighten the bolts -3-.

-- Install the chain tensioner -1- and tighten the bolts -arrows-.

Fig 15: Bolts And Chain Tensioner

Courtesy of AUDI OF AMERICA, LLC

-- Use the Adapter: T40266 to turn the intake camshaft in the direction of -arrow 1-. Then slide the Camshaft Lock: T40271/2 out of the chain sprocket splines in the direction of -arrow 2- and release the tension on the camshaft.

Fig 16: Identifying Assembly Tool T40266 And Camshaft Clamp T40271/2

Courtesy of AUDI OF AMERICA, LLC

-- Remove the Camshaft Lock: T40271/2 .

-- Check the adjustment. The painted chain links -arrows- must line up with the markings on the chain sprockets.

Courtesy of AUDI OF AMERICA, LLC

-- Install the chain tensioner -2- and tighten the bolt -1-. Remove the Locking Pin (3 pc.): T40011 . The oil pump chain tensioner bracket must make contact in the opening on the oil pan upper section -arrow-.

Fig 17: Identifying Chain Tensioner

Courtesy of AUDI OF AMERICA, LLC

-- Install the bolts -arrows- and tighten them. Tightening specification. Refer to -item : Bolt.

Fig 18: Identifying Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Coat the holes -arrows- with engine oil.

Courtesy of AUDI OF AMERICA, LLC

-- Check if the adapter sleeve -1- is installed. (Not present on every bearing bracket.)

Carefully connect the bearing bracket without tilting - risk of damage.

Fig 19: Identifying Bolts
Courtesy of AUDI OF AMERICA, LLC

-- Mount the bearing bracket and the bolts -arrows- hand-tight.

-- Remove the Tensioner Locking Tool: T40267 .

Fig 20: Securing Chain Tensioner With T40267

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the bearing bracket bolts. Refer to Figure.

-- Install the control valves -item : Control Valves.

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

TIP:

Due to the ratio, the painted chain links no longer match up after the engine has been turned.

Install in reverse order of removal. Note the following:

-- Remove the turning over tool and install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER, REPLACING .

-- Install the upper timing chain cover. Refer to TIMING CHAIN COVER, REMOVING AND INSTALLING, ENGINE WITH TWO CAMSHAFT ADJUSTERS .

There may be additional procedures depending on the model. Refer to CHAIN DRIVE .

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