Removing and installing camshaft without AVS: Audi TT Mk2 (CCTA, CCZA, CDAA, CESA, …)

🧭 Before you start

Fits: Audi TT Mk2 (8J, 2006–2014)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Renewed: bolts for cylinder head cover

Don't miss

• Disregard item (3).
• Turn vibration damper to "“TDC”" position using counterhold tool T10355.
• Use a waterproof pen to mark camshaft timing chain and cylinder head (arrows) relative to markings on chain sprockets (1).
• Use a waterproof pen to mark camshaft timing chain relative to guide rail of timing chain (2) as well.
• Mark camshaft chain sprockets relative to camshaft clamp T40271/1 and camshaft clamp T40271/2(arrows).

🔧 Engine codes this applies to

📋 Procedure

1. Remove engine cover panel (arrows).
2. Unscrew bolts (arrows) and remove air duct.
3. Detach air duct at bottom together with air hose.
4. Unplug electrical connector (1) from air mass meter G70.
5. Detach air intake hose (2).

6. Unscrew bolt (4) and remove air cleaner housing. [Note: Disregard item (3).]
7. Remove noise insulation General body repairs, exterior66Noise insulation; Exploded view - noise insulation.
8. Remove noise insulation (right-side) (arrows).
9. Remove noise insulation frame General body repairs, exterior50Lock carrier; Exploded view - lock carrier.
10. Remove bolts (arrows).
11. Remove air pipe (lift clips (items 1 and 2)).
12. Detach connector from camshaft control valve 1N205(1).
13. Unscrew bolts (arrows) and remove camshaft control valve 1N205.
14. Unscrew bolts (1 to 5) and remove timing chain cover (top).
15. ⚠ The timing valve has a left-hand thread. — Depending on version, turn assembly tool T10352 or assembly tool T10352/1 in direction of (arrow) to remove timing valve.
16. Remove bolts (arrows) and detach bearing saddle.
17. Turn vibration damper to "“TDC”" position using counterhold tool T10355.
18. Use a waterproof pen to mark camshaft timing chain and cylinder head (arrows) relative to markings on chain sprockets (1).
19. Use a waterproof pen to mark camshaft timing chain relative to guide rail of timing chain (2) as well.
20. Remove sealing plug (arrow).
21. Remove bolts (arrows).
22. Remove bolt (arrow).
23. Screw in assembly lever T40243(arrows).
24. Lift locking element for chain tensioner; to do so, insert scriber or suitable screwdriver in hole of chain tensioner in direction of (arrow 1), press assembly lever T40243 slowly in direction of (arrow 2) and hold in place.
25. Hold chain tensioner in position with locking pin T40011.
26. Screw in assembly lever T40243(arrows).
27. Compress circlip (arrow) for chain tensioner, press assembly lever T40243 slowly in direction of (arrow) and hold in place.
28. Hold chain tensioner in position with locking tool T40267.
29. Remove assembly lever T40243.
30. Bolt camshaft clamp T40271/2 onto cylinder head and slide into teeth on chain sprocket in direction of (arrow 2); if necessary, use spanner to turn inlet camshaft in direction of (arrow 1).
31. Remove bolt (1) and guide tensioning rail (2) downwards.
32. Bolt camshaft clamp T40271/1 onto cylinder head.
33. Use spanner to turn exhaust camshaft in direction of (arrow 1) and slide camshaft clamp T40271/1 into teeth on chain sprocket in direction of (arrow 2). [Note: Mark camshafts relative to camshaft clamp T40271/1 and camshaft clamp T40271/2.If using new camshafts: Transfer markings made on old camshafts onto new camshafts.It will take much more time to install the new camshafts if the markings are not applied.]
34. Mark camshaft chain sprockets relative to camshaft clamp T40271/1 and camshaft clamp T40271/2(arrows).
35. Use screwdriver to release catch and press off top guide rail (1) forwards.
36. Remove camshaft timing chain from camshaft sprockets.
37. ⚠ Avoid damage to valves and piston crowns.Do not turn the crankshaft after the camshaft timing chain has been removed from the cylinder head. — Use spanner to turn inlet camshaft in direction of (arrow 1) and slide camshaft clamp T40271/2 out of teeth on chain sprocket in direction of (arrow 2) and move camshaft into rest position.
38. Use spanner to turn exhaust camshaft in direction of (arrow 1) and slide camshaft clamp T40271/1 out of teeth on chain sprocket in direction of (arrow 2) and move camshaft into rest position.
39. Release electrical connectors at all ignition coils and unplug from ignition coils simultaneously.
40. Remove ignition coils using puller T40039.
41. Disconnect crankcase breather hoses (1 and 2).
42. Remove bolts (arrows) and detach crankcase breather.
43. Detach lines (1 and 3).
44. Unplug electrical connector (2) from Hall sender G40.
45. Remove high-pressure pump .
46. Remove vacuum pump Brake system47Vacuum system; Removing and installing vacuum pump.
47. Remove cylinder head cover bolts in the sequence (1 ... 6).
48. Detach cylinder head cover.
49. Detach camshafts.
50. ⚠ Protect lubrication system and bearings against contamination.Cover exposed parts of the engine. — Dirt and sealant residue must not be allowed to get into the cylinder head. [Note: The sealing surfaces must be free of oil and grease.Ensure that all roller rocker fingers contact the valve ends correctly.Silicone sealant Electronic parts catalogueNote expiry date of silicone sealant.The cover must be installed within 5 minutes after applying the silicone sealant.]
51. Remove sealant remaining on cylinder head with flat scraper.
52. ⚠ Protect lubrication system and bearings against contamination.Cover exposed parts of the engine. — Remove sealant remaining in groove of cylinder head cover and on sealing surfaces, e.g. using a rotating plastic brush.
53. Clean sealing surfaces; they must be free of oil and grease.
54. Cut off nozzle of tube at front marking (nozzle ∅ approx. 2 mm).
55. Transfer markings made on old camshafts onto new camshafts.
56. Oil running surfaces of both camshafts.
57. Fit camshafts in cylinder head, recesses (arrows) must face each other.
58. Renew bolts for cylinder head cover.
59. Apply silicone sealant onto clean sealing surface of cylinder head cover, as illustrated (arrows). [Note: The cylinder head cover must be installed within 5 minutes after applying the silicone sealant.The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe.Note the use-by date of the sealant.]
60. Tighten bolts in several stages; tightening sequence . [Note: Take care to keep cylinder head cover straight.]

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