9/24/2017 Camshaft Timing Chain Removal and Installation Engine Mechanical 2002 Audi A6/S6/Quattro/Allroad MotoLogic
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1 2002 A6/S6/Quattro/Allroad The information in this article comes from a service manual containing information that applies to the following engine code: BAS. Section Info: Report a problem with this article Crankshaft, Cylinder Block 4 Removal and Installation 4.7 Camshaft Timing Chain Special tools and workshop equipment required Crankshaft Holder Trim Removal Wedge (2x) 1/11
2 Oil Collecting and Extracting Device -V.A.G Multipoint Socket -T Camshaft Locator -T (quantity: 2) Setting Gauge -T Key -T Engine and Transmission Holder -VAS Two 3.3 mm drill bits Removing Drain engine oil. Refer to Maintenance Procedures; Rep. Gr. 03. Remove the engine. Refer to 4.2 Engine, Removing, page 18. Separate engine-/transmission unit. Refer to 4.3 Engine and Transmission, Separating, page 31. Secure engine on -VAS Refer to 1.1 Engine, Securing on Engine and Transmission Holder, page 6. Remove drive plate. Refer to 4.4 Drive Plate, page 78. Remove covers for timing chains. Refer to 4.6 Timing Chain Covers, page 80. Install -T at rear on crankshaft using 2 old drive plate bolts. Rotate crankshaft in direction of engine rotation -arrow- to Top Dead Center (TDC) ignition timing. Slits -arrows- at front in camshafts must stand parallel at same height with upper edge of cylinder head. 2/11
3 Rotate camshafts at hex head slightly back or forth if necessary so that -T can be inserted. If -T cannot be inserted, rotate crankshaft 1 rotation (360 ) further. Remove camshaft locator again. Remove drain plug. Install the in the hole (20 Nm). Rotate the camshaft back and forth slightly if necessary to completely center the holder. Push glide track of chain tensioner for left timing chain in direction of -arrow- and pull off chain tensioner using a 3.3 mm drill bit -1-. Mark running direction of left timing chain with paint. Remove bolts -1 and 2- for camshaft chain sprocket or camshaft adjuster using -T Remove camshaft chain sprocket, camshaft adjuster and timing chain. 3/11
4 Push glide track of chain tensioner for right timing chain in direction of -arrow- and pull off chain tensioner using a 3.3 mm drill bit -1-. Mark running direction of right timing chain with paint. Remove bolts -1 and 2- for camshaft chain sprocket or camshaft adjuster using -T Remove camshaft chain sprocket, camshaft adjuster and timing chain. Installing Secure crankshaft in TDC position using Drive chain for timing mechanism installed, refer to 4.9 Timing Mechanism Drive Chain, page 120. Always replace bolts that are tightened to torque as well as O- rings and gaskets. When turning camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged. Rotate inner part and outer part of both camshaft adjusters against each other up to lock position -arrows-. Inner part and outer part must not be able to be against each other in lock position (slight play can still be felt) Check whether camshafts of both cylinder heads stand in TDC position. Slits -arrows- at front in camshafts must stand parallel at same height with upper edge of cylinder head. 4/11
5 Insert -T into camshafts of left cylinder head, to do this rotate camshafts back or forth at hex head if necessary. Insert -T into camshafts of right cylinder head, to do this rotate camshafts back or forth at hex head if necessary. Replace all four camshaft bolts. Assemble left timing chain with chain sprocket and camshaft adjuster. Loosely screw in bolts -1 and 2-. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip. Assemble right timing chain with chain sprocket and camshaft adjuster. Loosely screw in bolts -1 and 2-. Chain sprocket and camshaft adjuster must be able to still be rotated on camshaft and must not tip. 5/11
6 Remove Using -T40049-, rotate crankshaft approximately 30 in opposite direction of engine rotation -arrow-. Pull drill out of alignment hole, which loosens the left chain tensioner. Insert as depicted in illustration and bring chain tensioner into contact with Lightly pressing in an extra 0.5 mm is permitted. Pull drill out of alignment hole, which loosens the right chain tensioner. Insert as depicted in illustration and bring chain tensioner into contact with Lightly pressing in an extra 0.5 mm is permitted. 6/11
7 Using -T40049-, rotate crankshaft in direction of engine rotation -arrow- to TDC ignition timing. If rotated unintentionally beyond TDC, turn back crankshaft again approximately 30 and set to TDC again. Screw into hole, if necessary rotate crankshaft very slightly back and forth to completely center the holder. Tightening specifications: 20 Nm. Tighten camshaft bolt -1- on exhaust camshaft of left cylinder head to initial tightening specifications. Tightening Specifications: 40 Nm. Secure the hall sensor wheel on the left cylinder head intake camshaft adjuster using the -T Place -T on bolt -1-. Tighten camshaft bolt -2- on intake camshaft to initial tightening specifications. Tightening specifications: 40 Nm. 7/11
8 Secure the Hall sensor wheel on the right cylinder head intake camshaft adjuster using the -T Place setting gauge -T on bolt -2-. Tighten camshaft bolt -1- on intake camshaft to initial tightening specifications. Tightening specifications: 40 Nm. Remove setting gauge. Tighten camshaft bolt -2- on exhaust camshaft of right cylinder head to initial tightening specifications. Tightening specifications: 40 Nm. -T must not be used as a counter holder for final tightening of camshaft bolts. Remove -T on both cylinder heads. Tighten camshaft bolt -1- on exhaust camshaft of left cylinder head to final tightening specifications. Tightening specifications: 100 Nm + 90 ( 1/4 turn). 8/11
9 Secure hall sensor wheel on camshaft adjuster of intake camshaft of left cylinder head using -T Place -T on bolt -1-. Tighten camshaft bolt -2- on intake camshaft to final tightening specifications. Tightening specifications: 100 Nm + 90 ( 1/4 turn). Secure hall sensor wheel on camshaft adjuster of intake camshaft of right cylinder head using -T Place -T on bolt -2-. Tighten camshaft bolt -1- on intake camshaft to final tightening specifications. Tightening Specifications: 100 Nm + 90 ( 1/4 turn). Remove setting gauge. Tighten camshaft bolt -2- on exhaust camshaft of right cylinder head to final tightening specifications. Tightening specifications: 100 Nm + 90 ( 1/4 turn). Remove /11
10 Using -T turn crankshaft two complete rotations in direction of engine rotation -arrow- until crankshaft stands at TDC again. Slits -arrows- at front in camshafts must stand parallel at same height with upper edge of cylinder head. Install the in the hole (20 Nm). Rotate the camshaft back and forth slightly if necessary to completely center the holder. Insert -T into camshafts of left cylinder head. 10/11
11 Insert -T into camshafts of right cylinder head. If camshaft locators cannot be inserted, repeat adjustment. Pull out Remove -T on both cylinder heads. Remove Screw sealing plug of TDC marking with new sealing ring into upper oil pan. Further installation is performed in reverse order of removal, noting the following: Install covers for timing chains page 88. Install drive plate. Refer to 4.4 Drive Plate, page 78. Bolt transmission to engine and install engine-/transmission unit. Refer to 4.4 Engine, Installing, page 34. Tightening Specifications Component Nm Camshaft bolts Sealing plug in upper oil pan 35 6) 90 corresponds to a 1/4 turn 7) Replace the bolts. 6) 7) 11/11
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