Removing and installing drive chain for valve gear and camshaft timing chain — AUDI

🧭 Before you start

Set TDC with the camshaft bar fitted, remove the chain tensioner and both timing covers and mark chain direction. Remove the guide rail, timing chain, then the drive chain and sprockets from the intermediate shaft. Refit the drive chain with a new sprocket bolt, set the tensioner and fit the timing chain with the copper links on the marks. Turn the engine 2 rotations, recheck timing, then seal and refit both covers, renew the oil seals and refit the ancillaries.

Fits: Audi A3 (8P, 2003–2012)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Renewed: function of chain tensioner

Don't miss

• Mark chain rotation direction with paint; never punch or notch the chains.
• Align the copper-coloured chain links with the adjuster and sprocket markings.
• Renew the intermediate shaft sprocket bolt.
• Press the tensioning rail by hand while turning the engine to stop the chain jumping.
• Fill the 3 mm bores in the head gasket with sealing compound before fitting covers.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 3 workshop diagrams for BDB

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Turn the crankshaft to the TDC marking (arrow) in the normal direction of rotation via the securing bolt on the vibration damper.
2. Cams (A) of cylinder 1 must face each other.
3. At the same time insert camshaft bar T10068 A in the slots on both camshafts; if necessary, turn the crankshaft 1 rotation further.
4. Mark and unplug the electrical connectors:
5. Unscrew chain tensioner for camshaft timing chain (arrow).

6. Unscrew bolts (1 ... 3) and remove timing chain cover (top) from cylinder head horizontally. Take care not to damage the cylinder head gasket when removing.
7. Unscrew bolts and remove lower cover (arrow) for timing chains horizontally from cylinder block. Take care not to damage the cylinder head gasket when removing.
8. Press out crankshaft oil seal (timing chain end) from the timing chain cover.
9. Mark rotation direction of timing chains with coloured arrows before removing (arrows).
10. ⚠ Avoid damage to timing chains.Do not mark chains by means of centre punch, notch or the like. — Unscrew bolts (arrows) and remove guide rail (1).
11. Remove camshaft timing chain from sprocket for intermediate shaft.
12. Remove camshaft timing chain carefully from behind the projection of the cylinder head gasket.
13. Loosen bolt (arrow) for chain sprockets on intermediate shaft approx. 1 turn.
14. To do so, apply counterhold tool T10069 to vibration damper for support.
15. Unscrew chain tensioner for drive chain for valve gear (arrows).
16. Unscrew bolt (arrow) and remove drive chain together with chain sprockets from intermediate shaft.
17. Note the marking for rotation direction (lower arrow) when reinstalling a used drive chain for valve gear.
18. Install drive chain together with large sprocket on intermediate shaft.
19. Turn intermediate shaft slightly if large sprocket cannot be fitted.
20. Check whether the crankshaft is still positioned at "“TDC”":
21. Fit small sprocket to intermediate shaft.
22. Renew bolt for chain sprockets of intermediate shaft.
23. Hand-tighten bolt (arrow) for chain sprockets.
24. Release locking spline in chain tensioner with a small screwdriver (arrow).
25. Press tensioning rail against chain tensioner and secure chain tensioner in this position (arrows).
26. Tighten bolt for chain sprockets (arrow).
27. Use counterhold tool T10069 to counterhold bolt for vibration damper.
28. Fit timing chain onto camshaft adjusters. Make sure that the two individual copper-coloured chain links (C) align with markings on camshaft adjuster. In some cases the camshaft adjuster (inlet side) must be turned slightly.
29. Fit timing chain onto small chain sprocket. The marking (B) must align with the copper-coloured chain link in the middle (A).
30. Install guide rail (1) and tighten bolts (arrows).
31. Remove camshaft bar T10068 A.
32. ⚠ Prevent timing chain from slipping.When turning the crankshaft, it is necessary to press the tensioning rail firmly against the camshaft timing chain manually (to replace function of chain tensioner) (arrow). — Turn crankshaft via the securing bolt for vibration damper 2 rotations in the normal direction of rotation until the marking is at TDC (arrow).
33. Cams (A) of cylinder 1 must face each other.
34. You should then be able to insert the camshaft bar T10068 A in the slots in both camshafts. [Note: The marked chain links will now be in an undefined position.]
35. Repeat adjustment of valve timing.
36. Clean any old sealing compound from the 3 mm bores (arrows) in the cylinder head gasket. [Note: With the cylinder head installed the holes in the cylinder head gasket are only half visible.]
37. Clean the sealing surfaces on the engine and on both covers; they must be free of oil and grease.
38. Check whether the dowel pins for lower cover for timing chains are inserted in the cylinder block.
39. Thinly coat clean surface of lower cover for timing chains (hatched surface in illustration) with sealing pasteElectronic parts catalogue. [Note: The lower cover for the timing chains must be installed within 5 minutes after applying the sealing paste.]
40. Tighten the bolts securing lower cover (arrow) for timing chains in diagonal sequence in stages.
41. Fill the 3 mm bores (arrows) in the cylinder head gasket with sealing compound (black)Electronic parts catalogue.
42. Renew the oil seals in the upper cover for timing chains .
43. Check if the dowel sleeves (2) and (3) are inserted in the upper cover for timing chains.
44. Insert a new oil seal (1) and a new seal (4).
45. Thinly coat clean surface of upper cover for timing chains (hatched surface in illustration) with sealing pasteElectronic parts catalogue.
46. Install upper cover for timing chains and tighten bolts in the following sequence:
47. Secure chain tensioner (arrow) for camshaft timing chain.
48. Turn the crankshaft 2 rotations in the normal direction of rotation and recheck valve timing.
49. Install crankshaft oil seal (timing chain end) .
50. Install cylinder head cover .
51. Install intake manifold 24.
52. Install thermostat housing .
53. Install sump .
54. Install dual-mass flywheel .
55. Install engine .
56. Fill up with engine oil and check oil level .

Other AUDI procedures

• Removing and installing air mass meter G70 – Audi A6 C6
• Removing and installing fuel pump control unit J538 - vehicles with 2.5 ltr. TFSI engine
• Checking vacuum unit for exhaust flap
• Removing and installing accelerator pedal module with accelerator position sender
• Checking fuel pump (electrical test) - TFSI and 6-cylinder engines
• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures