TDC?
#2
RE: TDC?
At TDC you'll notice that the oblong plates at the ends of the camshafts are pointing towards each other, with the big hole on each closer to the center of the engine. Also there's a little notch scratched in the accessory belt's main pulley that correponds to a little arrow in the plastic cover that's mounted directly behind it. this is only true for the 12v V6s.
#6
RE: TDC?
Belt drive assembly[/align]Removing and installing toothed belts[/align]
Removing:
βRemove ribbed belts ββ Remove engine cover -C- Remove bolts to do so -arrows-. [/ul]
ββ Remove pressure hoses -arrows- from intercoolers to left and right-hand pressure piping. [/ul]
ββ Remove pressure piping -1-. [/ul]
Note:
Be careful of retainer strips -2-.
ββ Remove ribbed belt tensioner -1-.
βRemove left and right toothed belt protector -2-.
βRemove central toothed belt protector -3-. [/ul]
ββ Turn over engine manually to TDC position. Markings -A- and -B- must be opposite each other. [/ul]
Note:
To turn over engine, use central crankshaft bolt.
βChecking camshaft positioning: The large drill holes on the camshaft sprocket fixing plates must face inwards and be directly in line with each other, otherwise rotate the crankshaft one more turn. [/ul]
βUnscrew sealing plugs from left-hand cylinder block. [/ul]
βThe TDC drilling in the crankshaft must be located directly behind the sealing plug hole (visually or by touch).[/ul]
Important:
[/align]
ββ Screw in 3242 crankshaft retainer into sealing plug hole and tighten.[/ul]
ββ Remove crankshaft vibration damper. [/ul]
Note:
It is not necessary to loosen the central bolt to remove the vibration damper.
ββ Remove ribbed belt idler wheel -arrows-.
βRemove toothed belt protector underneath vibration damper
-arrows-. [/ul]
Notes:
βBefore removing belt, mark direction of rotation with chalk or felt-tipped pen. Running a used belt in the opposite direction could destroy it. [/ul]
βToothed belt tensioner is oil damped and can only be compressed by applying an even pressure slowly. [/ul]
ββ Turn toothed belt tensioner -1- in direction of arrows with 8 mm Allen key until tensioning arm -2- has compressed tensioner -3- far enough that special tool T 400 11 fits into drill hole and plunger.
βInsert special tool T 400 11, release toothed belt tensioner.
βRemove toothed belts. [/ul]
Installing
βInsert camshaft retainer 3391 into fixing plates of both camshafts.
βRelease both camshaft bolts and unscrew approx. 5 turns.
βTake out camshaft retainer 3391.
ββ Pull off both camshaft sprockets using special tool T40001.
βRefit both camshaft sprockets with fitting plates and hand-tighten. [/ul]
Note:
The camshaft sprockets should be loose enough on the cones that they can be moved on the camshafts but not tilted.
ββ position belts on all sprockets as shown in the diagram.
βInsert camshaft retainer 3391. [/ul]
ββ Rotate belt tensioner -1- to the right in arrow direction with 8 mm Allen key until special tool T 400 11 can be removed. [/ul]
ββ Tension belts by turning with a torque wrench in direction of arrow and torqueing to 15 Nm.
βTighten camshaft sprockets. [/ul]
ββ Refit ribbed belt idler wheel -arrows-.
βRefit toothed belt protector underneath vibration damper -arrows-. [/ul]
ββ Install vibration damper. Watch for seating noses -arrows- on toothed belt sprocket. [/ul]
βFit toothed belt protector.
βRefit ribbed belts [/ul]
Tightening torque
Toothed belt sprocket on camshaft
55 Nm
Idler wheel
45 Nm
Toothed belt tensioner
20 Nm
Pulley on crankshaft
20 Nm
Toothed belt tensioner
10 Nm
Central crankshaft bolt 1)
200 Nm + 180Β°2)
1)The central bolt should be replaced.
2)2 times 90Β°further turning is permitted.
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#7
RE: TDC?
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#9
RE: TDC?
Servicing valve assembly[/align]Removing and refitting camshafts and camshaft adjusters[/align]
Removing
βCylinder head fitted [/ul]
ββ Remove noise insulation -arrows-.
βRemove front bumper: [/ul]
=> Body fitting work; Repair group 63; front bumpers; front bumper removal and refitting
βPlace lock carrier in service position [/ul]
=> Body exterior fitting work; Repair group 50; removal and refitting of lock carrier; lock carrier service position
βRemove ribbed belts
βRemove toothed belts Left-hand cylinder head:
βRemove left-hand cylinder head coverRight-hand cylinder head:
βRemove right-hand cylinder head cover All:
βUnscrew Hall effect sensor housing (10 Nm)
βUnscrew Hall effect sensor cover (20 Nm) and prise out carefully with screwdriver.
βInsert camshaft retainer 3391 into fixing plates of both camshafts.
βRelease both camshaft bolts and unscrew approx. 5 turns.
βTake out camshaft retainer 3391. [/ul]
ββ Pull off both camshaft sprockets using special tool T40001.
βCarefully prise out oil pipes for camshaft bearing lubrication from camshaft bearings using a screwdriver. [/ul]
Be careful that retainers do not break off when prising out.
ββ Secure camshaft adjuster with chain tensioner holder 3366. [/ul]
Note:
Camshaft adjuster can be damaged by over-tightening chain tensioner holder.
ββ Recheck TDC position of camshafts. [/ul]
Note:
Both markings on camshafts must be directly in line with both arrows on bearing caps.
βClean drive chain and sprockets opposite both arrows on bearing caps and mark fitting position in colour.[/ul]
Notes:
ββ Distance between both arrows or coloured marks is 16 links of the drive chain.
βThe groove on the exhaust camshaft is offset a little to the inside of the chain guide -1-.
βDo not mark chain by centre punching, grooving, etc.! [/ul]
ββ Unscrew camshaft adjuster retaining bolt -6-.
βUnbolt bearing caps 1, 3, 5 and 7 of the inlet and exhaust camshafts and lay them in sequence on a clean surface.
βLoosen bearing caps 2 and 4 of the inlet and exhaust camshafts cross-wise and remove.
βRemove inlet and exhaust camshafts complete with camshaft adjuster. [/ul]
Installing
ββ Replace the bonded rubber bush of camshaft adjuster and apply sealant lightly to hatched surface. [/ul]
βSealant [/ul]
=> Parts List
βLay drive chain on camshaft sprockets as follows:
ββ If old drive chain is reused, offer up coloured marks -arrows- to grooves. [/ul][/ul]
ββ If a new drive chain is used, the distance between grooves -A- and -B- on the camshafts must correspond to 16 links of the drive chain. The illustration shows where the 1st and 16th link must be placed on the sprockets.
βThe groove-A- is offset a little to the inside of the chain guide -1-. [/ul]
Push in camshaft adjuster under chain (2nd mechanic needed).
Lay camshafts with drive chain and camshaft adjuster in cylinder head.
Oil camshaft contact surfaces. [/ul]
Notes:
βFitting sleeves for bearing cap and camshaft adjuster must be in position in cylinder head.
βWhen refitting bearing cap, ensure that cap ID is readable from inlet side of cylinder head. [/ul]
βTighten camshaft adjuster (taking care of fitting sleeves).
ββ Tighten bearing caps 2 and 4 of the inlet and exhaust camshaft cross-wise (taking care of fitting sleeves).
βRefit both bearing caps to inlet and exhaust camshaft sprockets. [/ul]
βRecheck setting of camshafts.
ββ Both markings on camshafts must be directly in line with both arrows on bearing caps -arrows-. [/ul][/ul]
ββ Distance between both arrows on bearing caps or coloured marks is 16 links of the drive chain.
βThe groove on the exhaust camshaft is offset a little to the inside of the chain guide -1-. [/ul][/ul]
ββ Apply sealant lightly to hatched surface of double bearing cap -1- and bearing cap -7- [/ul]
ββ ...and replace bearing cap (taking care of fitting sleeves). [/ul]
βSealant [/ul]
=> Parts List
βReplace remaining bearing caps (taking care of fitting sleeves).
βReplace oil pipes for camshaft bearing lubrication and install.
βReplace inlet and exhaust camshaft seals, fit βRemoving chain tensioner holder 3366. [/ul]
Notes:
βEngine must not be started for approx. 30 minutes after fitting new tappets. Hydraulic compensating units must seat themselves (otherwise valves impact pistons). Then turn crankcase over twice.
βTurn over engine carefully at least twice after working on valve gear to endure that valves do not impact when starting. [/ul]
ββ Seal bearing cover/cylinder head joints
βApply a small quantity of sealant to the 4 edges on the cylinder head mating surfaces or the seal-arrows- using a small screwdriver before replacing the cylinder head cover. [/ul]
βSealant [/ul]
=> Parts List
βRefit cylinder head cover βRefit toothed belts
βRefit ribbed belts Tightening torques[/ul]
Part
Nm
Bolts
M6
10
M8
20
Deviation of:
Bearing cap on cylinder head
10
Camshaft adjuster on cylinder head
10
Cover for Hall effect sensor on camshaft
25
Housing for Hall effect sensor on cylinder head
10
Camshaft sprocket on camshaft
55 Nm
Cylinder head cover
10
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#10
RE: TDC?
Like I said before, it is unneeded to place the car in the service position or pull nearly anything that is outlined in the book proceedure that avant 80 have posted. Heres the writeup, http://forums.audiworld.com/a6/msgs/616641.phtml