Camshaft Timing Chain, Removing from Camshafts Audi TT 8N

Special tools, equipment, and material required

Scheme 107

1. Camshaft plate T10068
2. Gasket sealant, black, Part No AMV 174 04 01
3. Gasket paste, Part No. AMV 188 001 02

Removing

1. Engine in vehicle

1. Drain coolant. Refer to «Cooling system, draining and filling»(ref-276269-S04050758062008010300000) .
2. Remove intake manifold. Refer to «Intake manifold, removing and installing»(ref-276269-S38653353982008010300000) .
3. Disconnect electrical connector for Mass Air Flow (MAF) sensor -G70-.

Scheme 108

1. Remove bolts -1- and -3-.
2. Take out air cleaner housing.

1. Unclip protective cover -1- for electrical wiring.
2. Fold bracket box upward (arrows).

1. Remove fuse box by releasing retaining tabs (arrow).

Note. The wires remain connected.

1. Remove carrier (arrows).

Scheme 109

1. Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor -G62-.

Scheme 110

1. Disconnect coolant hoses at connections indicated (arrows).

Scheme 111

1. Remove bolts (arrows).
2. Swing bracket for secondary air injection hose forward.

Scheme 112

1. Remove bolt (arrow) on bracket for wiring harness.

Scheme 113

1. Remove thermostat housing -2-. To do so, press coolant pipe -1- toward coolant pump with an assembly lever.

Scheme 114

1. Disconnect air hose -4- and vacuum hose -1- at combination valve for secondary air injection system.
2. Disconnect Ground cable -2-.
3. Disconnect coolant hoses -3- and -5-.
4. Place Throttle valve control module -J338- on bulkhead.

Scheme 115

1. Mark and disconnect electrical connectors

1 - Camshaft Position (CMP) sensor -G40

2 - Camshaft Position (CMP) sensor 2 -G163

3 - Valve -1- for camshaft adjustment -N205

4 - Camshaft adjustment valve 1 (exhaust) -N318

1. Disconnect electrical connector (left side) on cylinder head and move connector clear.

1. Disconnect fuel supply line -1- and fuel return line -2- by pressing release tabs.
2. Unscrew and move clear all electrical connectors on cylinder head and lay them back together with fuel rail.

Scheme 116

1. Unscrew cylinder head cover bolts in sequence -11...1-.

Scheme 117

1. Turn crankshaft to TDC marking (arrow) in normal direction of rotation via securing bolt on vibration damper...

Scheme 118

1. Simultaneously insert camshaft plate T10068 into grooves on both camshafts. If necessary, turn crankshaft 1 rotation further.

Scheme 119

1. Remove bolt for camshaft timing chain tensioner (arrow).

Scheme 120

1. Remove bolts -1...3- and remove upper cover for camshaft timing chain from cylinder head horizontally. Take care not to damage cylinder head gasket when removing.

Scheme 121

1. Remove bolts (arrows) and remove guide rail -1-.
2. Remove camshaft plate T1068.

Note. The camshaft plate T10068 must not be inserted when loosening and tightening the securing bolts for the camshaft adjuster.

Scheme 122

1. Unscrew securing bolt at camshaft adjuster (intake side). Counterhold with open end wrench (32 mm) on hex flats of camshaft.
2. Remove camshaft adjuster (intake side).

Scheme 123

1. Unscrew securing bolt at camshaft adjuster (exhaust side). Counterhold with open end wrench (32 mm) on hex flats of camshaft.
2. Remove camshaft adjuster (exhaust side).
3. Remove camshaft timing chain over valves for camshaft adjustment and set aside.

Installing

1. Install guide rail -1- and tighten bolts (arrows).

1. Recheck TDC position of crankshaft (arrow)

1. Check TDC position of camshafts

It must be possible to insert camshaft plate T10068 into both camshaft grooves...

Scheme 124

1. ..If necessary, turn camshafts to correct position at hex flats (arrows) using an open end wrench (32 mm).

Note. The crankshaft must not be at TDC at any cylinder when the camshafts are turned. Otherwise, there is a risk of damage to the valves and piston crowns.

1. First install camshaft adjuster for intake side.

Scheme 125

1. Turn sender wheel -1- clockwise (arrow) in camshaft adjuster as far as stop.

Note. The camshaft plate must not be used as a counterhold.

Scheme 126

1. Tighten camshaft adjuster (intake side) in this position to intake camshaft finger-tight.

1. Contact surface of sender wheel at bolt head must be dry when installing
2. Inscription "24E" item -1- and tooth just behind it -2- must align with notch -3- in valve timing housing.

1. Lay camshaft timing chain in this position tautly onto sprocket of camshaft adjusted (intake side).

Scheme 127

1. Count exactly 16 rollers of timing chain starting from inscription "24E" on camshaft adjuster (intake side) moving toward exhaust side.
2. Place tooth at inscription "32A" on camshaft adjuster (exhaust side) exactly behind 16th roller of chain.

1. There should be now 16 chain rollers between teeth.
2. Inscription "32A" and tooth just behind it must also align with notch in valve timing housing.

Scheme 128

1. Turn sender wheel -2- clockwise (arrow) in camshaft adjuster -1- (exhaust side) as far as stop.
2. Tighten camshaft adjuster (exhaust side) in this position to exhaust camshaft finger-tight.

1. Contact surface of sender wheel at bolt head must be dry when installing.

Note. When turning the crankshaft, it is necessary to press the guide rail firmly against the camshaft timing chain manually (instead of using the tensioning element) -arrow- to prevent the chain from slipping.

1. Turn crankshaft via securing bolt for vibration damper 2 revolutions in normal direction of rotation until marking is at TDC (arrow)...

1. ..and simultaneously be able to insert camshaft plate T10068 in both camshaft grooves.

If the camshaft plate cannot be inserted

1. Repeat adjustment of valve timing.

Scheme 129

1. Clean any old sealing compound from 3 mm bores (arrows) in cylinder head gasket.
2. Fill 3 mm bores in cylinder head gasket with sealing compound (black) AMV 174 04 01.

Note. With the cylinder head installed the holes in the cylinder head gasket are only half visible.

1. Replace oil seals in upper cover for camshaft timing chain. Refer to «Oil seals in upper cover for camshaft timing chain, removing and installing»(ref-276269-S31378565982008010300000) .
2. Clean sealing surfaces.

1. Sealing surfaces must be free of grease and oil.

Scheme 130

1. Check if dowel sleeves -2- and -3- are inserted in upper cover for camshaft timing chain.
2. Insert a new oil seal -1- and a new seal -4-.
3. Thinly coat clean surface of upper cover for camshaft timing chain (hatched surface in illustration) with sealing past AMV 188 001 02.

Note. Also apply a thin coat of sealing paste to the surface beneath the cylinder head gasket (do not kink gasket). The upper cover for the camshaft timing chain must be installed within 5 minutes after applying the sealing paste.

1. Install upper cover for camshaft timing chain and tighten bolts in following sequence

1 - Tighten bolts -1- and -2- to 5 Nm

2 - Tighten bolts -3- to 23 Nm

3 - Tighten bolts -1- and -2- to 10 Nm

1. Secure chain tensioner (arrow) for camshaft timing chain.
2. Turn crankshaft 2 revolutions in normal direction of rotation and recheck valve timing.
3. Install cylinder head cover. Refer to «Cylinder head cover, removing and installing»(ref-276269-S10542814972008010300000) .
4. Install intake manifold. Refer to «Intake manifold, removing and installing»(ref-276269-S38653353982008010300000) .

1. Install thermostat housing. Refer to «Thermostat housing, removing and installing»(ref-276269-S29370771572008010300000) .

Tightening torques

1) Replace bolt

2) 90° equals one quarter turn