Audi Workshop Service and Repair Manuals

Removing and installing camshaft housing Special tools and workshop equipment required

t  Hose clamps for hoses up to 25 mm -3094- t  Sealant → Electronic parts catalogue Removing –  Remove camshaft timing chain → Chapter.

WARNING The fuel system operates at extremely high pressure. This can cause injury. The fuel pressure in the high-pressure section of the injection system must be reduced to a residual pressure prior to opening the system. –  Reduce fuel pressure in high-pressure section of injection system → Rep. Gr.24. –  Remove union nuts -arrows- and bolt -1- and detach high-pressure pipe.   Note Disregard -item 2-.

–  Remove bolts -arrows- and detach heat shield for turbocharger.

–  Remove bolt -4- and detach crankcase breather hose from turbocharger -arrow-.   Note Disregard -items 1, 2, 3-.

–  Clamp off coolant hoses with hose clamps -3094- as shown in illustration. –  Remove bolts -1, 3, 4, 5-. –  Disconnect coolant lines from turbocharger and move clear to one side.   Note Disregard -item 2-.

–  Remove bolts -2- and -3- and take off retaining plate.   Note Disregard -items 1, 4-.

–  Slacken camshaft housing bolts in the sequence -15 ... 1-.   Note Bolt -14- below turbocharger remains in camshaft housing. –  Carefully release camshaft housing from bonded joint and detach. –  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., → Chapter. l  No piston at “TDC”.   Note Renew oil strainer and seals in cylinder head.   Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine. –  Carefully remove sealant residue on cylinder head and camshaft housing. –  Clean sealing surfaces; they must be free of oil and grease.

l  Camshaft clamp -T10171 A- must be fitted and secured with a bolt -arrow- before installing camshaft housing.

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

–  Apply a thin and even layer of sealant to the clean sealing surface of the camshaft housing at grey-shaded areas -1 ... 5- shown in illustration.

–  Fit new oil strainer -1- into cylinder head. –  Fit 4 seals -2- into cylinder head.

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 dowel pins -arrows- 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 high-pressure pipe → Rep. Gr.24. –  Install camshaft timing chain → Anchor.