Audi Workshop Service and Repair Manuals

Removing and installing camshafts

Special tools and workshop equipment required

t	Two-arm puller -T40001-

t	Counterhold tool -3036-

t	Locking pin -T10060 A-

t	Support bracket -10 - 222 A-

t	Thrust piece -3334-

t	Shackle -10 - 222 A /12-

Removing Engine code BLX, BLY, BLR, BVY, BVZ –  Remove toothed belt → Chapter. Engine code AXW, BMB, BHD

–  Lift off engine cover panel -arrows-.

–  Remove noise insulation (centre) - fasteners -1 ... 3-.

–  Remove noise insulation (right-side) - fasteners -1 ... 3-.   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection. –  Mark fuel supply and return lines.

–  Detach hose going to activated charcoal filter -1-. –  Disconnect fuel supply line -2- by pulling release tab. –  Disconnect fuel return line -3- by pulling release tab.

–  Disconnect vacuum line -1- going to activated charcoal filter by pressing release tab. –  Disconnect fuel supply line -2- by pulling release tab. –  Disconnect fuel return line -3- by pulling release tab.

–  Lift out activated charcoal filter from retainer with pipes connected -arrow-.

–  Unbolt bracket -3- for ACF. –  Unfasten bolt at filler neck of washer fluid reservoir -2-. –  Disconnect electrical wire for coolant shortage indicator switch at expansion tank -1-. –  Unbolt coolant expansion tank and lay it aside with pipes connected.   Note Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

–  To slacken poly V-belt, turn tensioner in direction of -arrow-.

–  Lock tensioner in position with locking pin -T10060A-. –  Take off poly V-belt. –  Remove locking pin -T10060A- from tensioner for poly V-belt.

–  Remove the bolts -arrows- and lift off toothed belt cover.   Note Engage carefully in toothed belt cover (centre) when installing.   WARNING The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).   Note Apply spanner to central bolt of crankshaft for turning engine.

–  Rotate engine to TDC of No. 1 cylinder by turning central bolt of crankshaft sprocket in normal direction of rotation. Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC of cylinder No. 1 -arrows-.

–  Position support bracket -10 - 222 A- on bolted flanges of wing panels. The spindles face forwards. –  Detach crankcase breather hose from oil filler neck. –  Attach hooks of spindles with shackles -10 - 222 A /12- to the lifting eyes. –  Take up weight of engine evenly with both spindles (but do not raise engine).

–  Remove bolts -1- and -2- and detach connecting bracket. –  Remove bolts -3 ... 6- and detach engine mounting.

–  Remove bolts -arrows- and take off engine support   Note To slacken the bolts for the engine support, raise or lower the engine slightly as necessary via the spindles on engine support bracket -10 - 222 A-.

–  Unscrew bolts for toothed belt cover (centre) -arrows- and remove toothed belt cover from engine.

–  Loosen nut on tensioning roller -arrow- several turns. –  Remove toothed belt. All vehicles (continued):

–  Loosen camshaft sprocket using counterhold -3036-.

–  Use puller -T40001-, claw -T40001/6- and claw -T40001/7- to pull off camshaft sprocket. –  Detach toothed belt cover (rear) from cylinder head. –  Remove camshaft adjuster → Chapter. –  Loosen retaining frame bolts evenly working from outside inwards and remove retaining frame. –  Carefully lift out the camshafts and place them down on a clean surface.

–  Remove old sealant from groove in retaining frame and from sealing surfaces. –  Make sure dirt and remnants of sealant do not drop into cylinder head. Installing   Note t  The sealing surfaces must be free of oil and grease. t  Pistons must not be at TDC. t  Ensure that all roller rocker fingers contact the valve ends correctly. –  Lubricate running surfaces of the camshafts with oil.

–  Insert camshafts carefully in the camshaft bearings of cylinder head. Cams -A- of cylinder 4 must face each other.

–  Apply an even, slightly projecting sealant bead into the clean groove of the retaining frame.   Note t  Do not apply the sealant thicker than prescribed. If necessary remove excess sealant with a lint-free cloth. t  No time should be allowed to elapse when fitting and securing retaining frame, as sealant starts to harden as soon as sealing surfaces make contact. t  Note the use-by date of the sealant.

–  Fit retaining frame so that it goes past the exhaust gas recirculation valve -N18--arrow-. –  Tighten bolts lightly in several stages, working from inside outwards.

–  Then tighten bolts in the sequence indicated to 8 Nm. –  Drive in cap → Item approx. 1...2 mm deep using thrust piece -3334-. –  Install camshaft oil seal → Chapter. –  Install toothed belt cover (rear). –  Insert parallel key into camshaft.

–  Install camshaft sprocket. To tighten bolt, hold camshaft sprocket in position using counterhold tool -3036-.   Note t  When turning the camshaft, the pistons must not be at TDC. This could otherwise result in damage to valves and pistons. t  Make sure parallel key is correctly seated. –  Install camshaft adjuster → Chapter. –  Install toothed belt: engine codes AXW, BMB, BHD → Chapter, engine codes BLX, BLY, BLR, BVY, BVZ → Chapter. –  Install cylinder head cover → Chapter.