Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Pin 3359
• ◆ VAS 5024 A
• ◆ Camshaft straightedge T10098
• ◆ Two-arm puller T40001

Removing

• ‒ → Remove oil dipstick -1- from guide tube.
• ‒ Unclip caps.
• ‒ Unscrew nuts -arrows- and remove engine cover.
• ‒ Reinsert oil dipstick in guide tube.

• ‒ Detach the cover and the electrical connector at the right headlight unit.
• ‒ → Disconnect fuel-feed line -2- and fuel-return line -1- at injection pump.
• ‒ Disconnect the electrical connection -3- at the sender -G71/-G72.
• ‒ Expose the wiring at the air duct pipe.
• ‒ Remove the air duct pipe on right side -arrows-.
• ‒ Remove upper toothed belt guard.

• ‒ → Remove air duct hose -1- from air duct pipe.
• ‒ Detach connector of air mass meter -3-.
• ‒ Unscrew bolts -4- and -5-.
• ‒ Remove vent hose -2- from rear of air cleaner housing.
• ‒ Take out air cleaner housing.

• ‒ → Remove lower air duct pipe -arrows-.

• ‒ → Remove noise insulation in centre and on right -arrows-.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with manual gearbox).

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with automatic gearbox).

Note:

Position crankshaft to TDC No. 1 cylinder with engine removed.

• ‒ Remove the exhauster => Fig.15-8.
• ‒ → Turn the bolts -1- by hand up to stop into the cylinder head.
• ‒ Lock the camshaft using camshaft straightedge T10098 as shown in the illustration.
• ‒ If the camshaft straightedge T10098 cannot be inserted, rotate crankshaft 1 additional turn (360°).

• ‒ → Lock injection pump sprocket using pin 3359.
• ‒ Loosen injection pump sprocket securing bolts -arrows-.

Note:

→ Never loosen the injection pump sprocket central nut -2-. Otherwise the injection pump basic setting is incorrectly adjusted and cannot be corrected again using workshop equipment.

• ‒ → Loosen the tensioning roller nut -arrow- by several turns.

• ‒ Remove the toothed belt from the camshaft toothed belt sprocket.
• ‒ → Unscrew the camshaft sprocket bolt by one half turn .
• ‒ Place the two-arm puller T40001 with claw T40001/2 -Item A- and the two-arm claw T40001/3 -Item B- centralised onto the camshaft sprocket.
• ‒ Pull off the camshaft sprocket using the two-arm puller. Counterhold using an open-end spanner -C- in the process.
• ‒ Removing camshaft toothed belt sprocket.

• ‒ Remove cylinder head cover => Page 15-9.
• ‒ Only remove bearing caps 5, 1 and 3. Loosen bearing caps 2 and 4 alternately and diagonally.
• ‒ Take out camshaft.

Installing

Installation is carried out in the reverse order; note the following:

Notes:

• ◆ When installing the camshaft, No. 1 cylinder cams must point upwards.
• ◆ → Before installing bearing caps, note bore offset and determine fitting location.
• ◆ Hose connections and hoses for charge air system must be free of oil and grease before assembly.
• ◆ Secure all hose connections with the correct hose clamps (same as original equipment):

=> Parts List

• ‒ Oil camshaft running surfaces.
• ‒ Tighten bearing caps 2 and 4 alternately and diagonally to 20 Nm.

• ‒ Install bearing caps 5, 1 and 3 and also tighten to 20 Nm.
• ‒ Attach camshaft sprocket and hand-tighten.
• ‒ Install cylinder head cover => Page 15-11.
• ‒ Install toothed belt (adjust valve timing) => Page 13-31.

Notes:

• ◆ Note all instructions on removing and installing the toothed belt .
• ◆ After installing the camshaft, wait for about 30 minutes before starting the engine. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons).
• ◆ After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.

Tightening torque