Audi Workshop Service and Repair Manuals

Removing and installing camshafts

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Camshaft fitting tool -T40094-

t	Camshaft fitting tool -T40095-

t	Clamping tool -T40096/1- for vehicles with two-piece camshaft gear

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Electronic parts catalogue

Removing l  Cylinder head installed. –  Remove engine cover panel -arrows-. –  Take toothed belt off camshaft sprocket and high-pressure pump sprocket → Chapter „Removing and installing toothed belt“. –  Remove cylinder head cover → Chapter.

–  Remove bolts -1- and detach camshaft sprocket.

–  Counterhold using counterhold tool -T10051- and loosen bolt -1- for camshaft hub. –  Unscrew bolt approx. 2 turns.

–  Apply puller -T10052- to camshaft hub and and screw bolts -1- into hub. –  Counterhold on hexagon flats (30 mm) of puller and screw in bolt -2- to pull off camshaft hub. –  Detach hub from taper of camshaft. –  Remove vacuum pump → Rep. gr.47.

–  Slacken retaining frame bolts in the sequence -24 ... 1-. –  Remove bolts and carefully release retaining frame from bonded joint. –  Mark fitting location of camshafts for re-installation and remove. Installing l  Tightening torques → Chapter „Valve gear - exploded view“   Caution Make sure axial bearings in retaining frame are not damaged. The camshafts MUST be installed using the camshaft fitting tool -T40094- as described in the following.

Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine.   WARNING Protect eyes against injuries. Wear safety goggles. –  Remove remaining sealant from cylinder head and retaining frame using rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease. –  Oil running surfaces of both camshafts.

Set up camshaft fitting tool -T40094- as follows: –  Secure supports -T40094/9- and -T40094/10- (with -T40094/11-) to base plate, as shown in illustration. If necessary, remove any supports already attached at these positions.

–  Fit support -T40094/1- onto position -F- and support -T40094/2- onto position -A-.

–  Place inlet camshaft in supports -T40094/1- and -T40094/2-. –  Turn inlet camshaft in such a way that it can be locked in „TDC“ position using locking device -arrow 1-. l  Recess -arrow 2- for cylinder head bolt must face outwards.

–  Place exhaust camshaft in supports -T40094/9- and -T40094/10-. –  Lock exhaust camshaft with top section -T40094/11-. l  The lug -1- on the top section must engage in the slot -2- in the camshaft, Vehicles with two-piece camshaft gear: –  Place clamping tool -T40096/1- on teeth of exhaust camshaft in such a way that the two arms of the tool engage on the two halves of the gear (one in each half, as shown in illustration). l  The wider arm must engage in the wider half of the gear. –  Tighten the clamping tool using the knurled wheel so that the faces of the gear teeth are in alignment. All vehicles (continued): –  Slide inlet camshaft towards exhaust camshaft, until gear teeth engage -arrows-.

–  Fit retaining frame -1- on camshafts. l  All camshaft bearings must be seated on the camshafts. –  Position camshaft fitting tool -T40095- and fix camshafts in position in retaining frame, as shown in illustration. –  Detach top section -T40094/11-.   Note

Note the use-by date of the sealant. –  Cut off nozzle of tube at front marking (nozzle Ø approx. 2 mm).

Caution Make sure excess sealant does not contaminate camshaft bearings. The beads of sealant must not be thicker than specified. –  Apply beads of sealant onto clean sealing surfaces of cylinder head as shown in illustration. l  Thickness of sealant beads: 2 ... 3 mm.   Note t  The retaining frame should be fitted and secured without delay, as the sealant starts hardening immediately. t  After installing the retaining frame, wait about 30 minutes for the sealant to dry. –  Take camshafts together with retaining frame, camshaft fitting tool -T40095- and, if necessary, clamping tool -T40096/1- out of camshaft fitting tool -T40094- and insert components carefully into cylinder head.

–  Screw in retaining frame bolts in the sequence -1 ... 24- evenly by hand until they make contact. l  The retaining frame should make contact with the cylinder head over the full surface. –  Tighten bolts → Fig.. –  Remove camshaft fitting tool -T40095- and, if necessary, clamping tool -T40096/1-. Remaining installation steps are carried out in reverse sequence; note the following: –  Install camshaft oil seal → Chapter. –  Drive new sealing cap → Item into cylinder head to a depth of approx. 1 ... 2 mm using suitable thrust piece. –  Install toothed belt (adjust valve timing) → Anchor. –  Install vacuum pump → Rep. gr.47. –  Install cylinder head cover → Chapter.   Caution Avoid damage to valves and piston crowns after working on valve gear. t  The hydraulic tappets have to settle; wait for approx. 30 minutes after installing camshafts before starting engine. t  Turn the crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.