How to Replace timing chain on Audi S4 3.0 TFSI 2009

Audi S4 3.0 TFSI 2009 timing chain change instructions and replacement interval. Full guide! 

Special tools

• Balancer shaft alignment tool – No.T40116.
• Camshaft adjuster pre-tensioning tool 1 – No.T10172.
• Camshaft adjuster pre-tensioning tool 2 – No.T10172/2.
• Camshaft locking tools – No.T40133/1/2.
• Camshaft sprocket adapter – No.T10035.
• Crankshaft locking pin – No.T40069.
• Crankshaft pulley bolt adapter – No.T40058.
• Crankshaft turning tool – No.T40049.
• Timing chain tensioner locking pin – No.T40071.
• Two-pin wrench – No.3212.

Special precautions

• Disconnect battery earth lead.
• Remove spark plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

• Timing chains located at rear of engine.
• Removal/installation of timing chain(s) requires:
  • Transmission removal.
  • Flywheel removal.
• Turn crankshaft in direction of rotation until threaded holes in camshafts point upwards [1] .
• Fit camshaft locking tools [2] . Tighten to 25 Nm.
• Remove blanking plug from cylinder block.
• Fit crankshaft locking pin [3] . Tighten to 20 Nm.
• Ensure balancer shaft can be locked in position [4] .
• Remove tensioner(s) to ease timing chain(s) removal/installation.
• Push plunger into tensioner housing and insert locking pin [5] , [6] & [7] .
• Slacken central bolt of each camshaft 1 turn [8] .

NOTE: If timing chains are to be reused, mark LH and RH chains before removal to ensure they are refitted in their original positions.

• Align camshafts.
• Fit camshaft locking tools [2] .
• Fit camshaft locking tool bolts. Tighten to 25 Nm.
• Tighten RH camshaft adjuster bolt and RH camshaft sprocket bolt in sequence [8] :
  • Pre-tension RH camshaft coupling chain.
  • Fit two-pin wrench to exhaust camshaft sprocket [9] .
  • Pre-tension RH exhaust camshaft sprocket in clockwise direction [9] .
  • Tighten exhaust camshaft sprocket bolt to 80 Nm [8] .
  • Maintain pre-tension on exhaust camshaft sprocket [9] .
  • Tighten inlet camshaft adjuster bolt to 80 Nm [8] .
  • Remove two-pin wrench [9] .
  • Tighten inlet camshaft adjuster bolt and exhaust camshaft sprocket bolt a further 90° [8] .
• Tighten LH camshaft adjuster bolt and LH camshaft sprocket bolt in sequence [8] :
  • Pre-tension LH camshaft coupling chain.
  • Fit camshaft adjuster pre-tensioning tools to LH inlet camshaft adjuster [10] .
  • Pre-tension LH inlet camshaft adjuster in clockwise direction [10] .
  • Tighten inlet camshaft adjuster bolt to 80 Nm [8] .
  • Maintain pre-tension on inlet camshaft adjuster [10] .
  • Tighten exhaust camshaft sprocket bolt to 80 Nm [8] .
  • Remove camshaft adjuster pre-tensioning tools [10] .
  • Tighten inlet camshaft adjuster bolt and exhaust camshaft sprocket bolt a further 90° [8] .

NOTE: Central bolt of camshaft adjusters MUST only be used once.

• Remove chain tensioner locking pin after repairs [7] .
• Remove crankshaft locking pin and camshaft locking tools [3] & [2] . Turn crankshaft 2 turns clockwise to TDC on No.1 cylinder.
• Fit camshaft locking tools [2] .
• Fit crankshaft locking pin [3] .
• If crankshaft locking pin cannot be fitted valve timing is incorrect. Repeat installation procedures.
• Remove crankshaft locking pin and camshaft locking tools [3] & [2] .
• Refit blanking plug for cylinder block. Renew seal ring.