Audi Workshop Service and Repair Manuals

Removing and installing camshaft housing Special tools and workshop equipment required

t  Puller -T10094 A- t  Sealant remover, commercially available t  Sealant → Electronic parts catalogue

Removing –  Remove coupling drive toothed belt → Chapter. –  Remove bolt -top arrow- securing rear cover -1- for toothed belt.

–  Remove bolts -arrows- and move wiring guide -1- clear to one side.

–  Apply puller -T10094 A- to all ignition coils -arrow-, pull out ignition coils and at the same time unplug electrical connectors at ignition coils for cylinders 1 ... 4.

–  Detach filler cap for oil filler neck. –  Unplug electrical connector -4- at Hall sender -G40-. –  Remove bolt -2- securing earth wire and bolts -arrows- securing wiring guide. –  Swivel wiring guide to the left and detach hose -3- from non-return valve.

–  Slacken camshaft housing bolts in the sequence -15 ... 1-. –  Carefully lift off camshaft housing. –  Mark original positions of roller rocker fingers and compensation elements for reinstallation. –  Remove roller rocker fingers together with compensation elements and put down on a clean surface. Installing l  Tightening torques → Fig. l  No piston at „TDC“.   Note Renew bolts for camshaft housing.   Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine. –  Remove sealant residue on cylinder head and camshaft housing using commercially available sealant remover. –  Clean sealing surfaces; they must be free of oil and grease.

–  Insert locking pins -D- on camshaft lock -T10016- all the way into locating holes in camshaft housing as follows: l  Through locating hole in inlet camshaft sprocket -C-. l  Through locating hole in exhaust camshaft sprocket. l  The knobs on locking pins must be on a level -line A-. –  Push retainer -B- onto inlet camshaft sprocket as far as stop.

–  Ensure all roller rocker fingers contact the valve ends -1- correctly and are clipped into their respective support elements -2-.

Caution Make sure lubrication system is not clogged by excess sealant. The sealant bead must not be thicker than specified. –  Apply a thin and even layer of sealant to the clean sealing surface of the camshaft housing at grey-shaded area shown in illustration.

–  Screw in 2 threaded threaded pins M6x70 -arrows- into cylinder head to guide camshaft housing.   Caution Make sure remnants of oil are removed before fitting, otherwise leakage can occur. Make sure sealing surfaces are free of oil when fitting camshaft housing. –  Carefully fit the camshaft housing vertically onto the threaded pins and dowel pins on cylinder head from above.   Note Make sure that camshaft housing is kept straight.

–  Tighten camshaft housing bolts → Fig..   Note After fitting camshaft housing, allow sealant to dry for approx. 30 minutes. Remaining installation steps are carried out in reverse sequence; note the following: –  Install cover (rear) for toothed belt → Chapter. –  Install coupling drive toothed belt → Chapter.