Audi Workshop Service and Repair Manuals

Removing and installing camshafts

Special tools and workshop equipment required

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Rack -T10262-

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Electronic parts catalogue

Removing –  Move lock carrier to service position → Chapter. –  Pull off engine cover panel -arrows-.

–  Detach vacuum line -3-.   Note Coolant hoses -1- and -2- remain connected.

–  Unscrew bolts -1- and nuts -2-. –  Remove bolts -arrows-. –  Remove exhaust gas recirculation cooler and lay it aside with coolant hoses connected.

–  Detach bracket for exhaust gas recirculation cooler from cylinder head -arrows-. –  Remove toothed belt → Chapter.

–  Pull out locking pins -3359- (2x). –  Remove securing bolts -arrows- for camshaft sprockets. –  Remove the camshaft sprockets from hubs.

–  Loosen securing bolt -1- for hub on inlet camshaft; use counterhold tool -T10051-.

–  Loosen securing bolt -1- for hub on exhaust camshaft; use counterhold tool -T10051-. –  Unscrew securing bolts of hubs approx. 2 turns.

–  Fit puller -T10052- on hub of inlet camshaft and screw bolts -arrows- into hub. –  Remove hub by screwing in bolt -1- while counterholding at hexagon flats (30 mm) of puller.

–  Fit puller -T10052- on hub of exhaust camshaft and screw bolts -arrows- into hub. –  Remove hub by screwing in bolt -1- while counterholding at hexagon flats (30 mm) of puller.

–  Remove bolts -2- and -4-.   Note The bolts -1-, -3- and -5- remain tightened.

–  Detach crankcase breather hose and vacuum hose from cylinder head cover -arrows-. –  Remove cylinder head cover bolts in the sequence -11 ... 1-. –  Remove cylinder head cover.

–  Loosen the lock nuts -2- of the adjuster screws -1- on all unit injectors. –  Unscrew the adjuster screws until each rocker arm touches the tappet spring of the unit injector.

–  Remove bolts -1-, -3- and -5-. –  Unscrew bolts -2- and -4- alternately in several stages.   Note Do not pull bolts out of rocker arm shaft so that components remain attached to shaft. If necessary mark position on rocker arm. –  Detach rocker arm shaft. –  Remove tandem pump → Rep. Gr.20.   Note The hoses can remain attached to the tandem pump.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-. –  Detach main connector for unit injectors and glow plugs.

–  Detach electrical connectors from glow plugs -A- and from unit injectors -B-.   Caution Only slacken or tighten the bolts at the retaining clips when removing the electrical wiring harness. If the electrical wiring harness is released at the retaining clips, the clips will become bent and this may lead to a break in the wiring because of the increased amount of play. –  Remove bolts -arrows- at retaining clips and move entire electrical wiring harness clear to one side.

–  Unscrew remaining 15 bolts for bearing frame evenly, working from the outside inwards.

–  Unscrew the 15 mm pressing-out bolts on the rack -T10262- anti-clockwise by hand as far as the stop. –  Position the rack -T10262- on the bearing frame as illustrated and tighten the 10 mm securing bolts to 10 Nm. –  Screw in the pressing-out bolts clockwise by hand until they make contact with the cylinder head bolts. –  Now tighten the pressing-out bolts evenly in the sequence 1 ... 4 (numbers are inscribed on the bolt heads) until the bearing frame detaches from the cylinder head. –  Remove the bearing frame.   Note Mark allocation of camshaft bearing shells on rear with a waterproof felt-tip pen. –  Take out camshafts.

Installing   Note Renew the bolts tightened with specified tightening angle. –  Remove sealant residue from bearing frame and cylinder block with rotating plastic brush or similar.   WARNING Wear safety goggles. –  Clean sealing surfaces; they must be free of oil and grease. –  Check whether the crankshaft is positioned at TDC. l  The crankshaft sprocket must be locked at cylinder 1 TDC using crankshaft stop -T10050- for engines with circular crankshaft sprocket, or crankshaft stop -T10100- for engines with oval crankshaft sprocket.   Note t  Make sure that the camshaft bearing shells are not interchanged. t  When installing the camshaft, make sure that the retaining lugs on the bearing shells are correctly seated in the bearing caps and the cylinder head. –  Lubricate running surfaces of camshafts.

–  Install camshafts in TDC position for cylinder 1: l  On both camshafts, the cams -1- and -2- for cylinder 1 must face upwards. l  The grooves -arrows- also face upwards.

–  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø).

–  Apply sealant onto the clean sealing surfaces of the bearing frame -arrows-. l  Width of sealant bead: 2 mm.   Note The bearing frame must be installed within 5 minutes after applying sealant.

–  Tighten the bolts -1 ... 20- evenly from the inside outwards. –  Turn bolts -1-, -3-, -5-, -7- and -9- of rocker arm shaft 90° (1/4 turn) further. Remaining installation steps are carried out in reverse sequence; note the following: –  Connect main connector for unit injectors and glow plugs. –  Adjust unit injectors → Rep. Gr.23. –  Install tandem pump → Rep. Gr.20. –  Install cylinder head cover → Chapter. –  Install oil seals for camshafts → . –  Install toothed belt (adjust valve timing) → Anchor. –  Install vibration damper → Chapter. –  Install poly V-belt → Chapter. –  Install exhaust gas recirculation cooler → Chapter. –  Install lock carrier with attachments → Rep. Gr.50.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten nuts -arrows-. –  Install bumper cover (front) → Rep. Gr.63.   Note t  After installing camshafts, wait for approx. 30 minutes before starting engine. The hydraulic tappets have to settle (otherwise valves will strike pistons). t  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 torques

Component	Nm
Bearing frame to cylinder head	20
Rocker arm shaft to cylinder head	20 + 90° 1)2)
Toothed belt cover (rear) to bearing frame	10 3)
Bracket for exhaust gas recirculation cooler to cylinder head	10
Stop for torque reaction support to lock carrier	28
Hose clips (9 mm wide)	3
Hose clips (13 mm wide)	5.5
l  1) Renew bolts. l  2) 90° = one quarter turn. l  3) Apply locking fluid when installing; refer to → Electronic parts catalogue for locking fluid.