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- Removing   Note t  Sealing surfaces at bottom of retaining frame and top of cylinder head may not be machined. t  The camshaft bearings are integrated into the cylinder head and retaining frame. Toothed belt must be slackened before removing retaining frame. t  Renew camshaft oil seal and sealing cap if retaining frame has been unfastened. –  Remove cylinder head cover → Chapter. –  Remove camshaft adjuster → Chapter. –  Remove toothed belt → Chapter.

–  Loosen camshaft sprocket using counterhold tool -3036-.

–  Use puller -T40001-, claw -T40001/6- and claw -T40001/7- to pull off camshaft sprocket. –  Detach toothed belt cover (rear) from cylinder head.

–  Unscrew retaining frame bolts in the sequence -6 ... 1- and carefully remove retaining frame. –  Remove camshafts together with drive chain from cylinder head. –  Make sure dirt and remnants of sealant do not drop into cylinder head. Installing l  Tightening torques → Chapter l  Tightening torques → Chapter   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.

–  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. –  Lubricate running surfaces of the camshafts with oil.

–  Position drive chain on chain sprockets as follows (with camshafts removed): –  Lubricate running surfaces of camshafts. l  Cams -A- of cylinder 4 must face each other. l  Recesses -arrows- on both camshafts must face each other. l  The side surfaces of the recesses should be positioned exactly vertical. –  Insert camshafts together with drive chain into cylinder head and chain tensioner.

–  Check TDC position of camshafts again. l  Cams -A- of cylinder 4 must face each other. l  Recesses -arrows- on both camshafts must face each other. l  The side surfaces of the recesses should be positioned in exactly vertical line to the cylinder head. –  Lubricate running surfaces of camshafts.

–  Apply an even, slightly projecting sealant bead into the clean groove of the retaining frame. Sealant → Parts catalogue   Note t  Do not apply the sealant thicker than prescribed. 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-. –  Renew bolts for retaining frame. –  Tighten bolts lightly in several stages, working from inside outwards.

–  Tighten bolts in several stages; tightening sequence → Fig..   Note Take care to keep retaining frame straight.

–  Then check that camshafts are in TDC position (insert camshaft clamp -T10252- as far as stop).   Note t  If necessary, turn camshafts slightly backwards or forwards when inserting camshaft clamp -T10252-. t  Disregard -arrows-. –  If it is not possible to insert camshaft clamp -T10252-, retaining frame must be removed and camshafts installed for a second time → Anchor. –  Detach camshaft clamp -T10252-. –  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 toothed belt → Chapter. –  Install camshaft adjuster → Chapter. –  Install cylinder head cover → Chapter. Further assembly is basically carried out in reverse order of dismantling.