Audi Workshop Service and Repair Manuals

Removing and installing camshafts and camshaft adjuster Special tools and workshop equipment required

t  Chain tensioner retainer -3366- t  Sealant → Parts catalogue

Removing –  Remove noise insulation -arrows-. –  Remove front bumper → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50. –  Remove toothed belt → Chapter. –  Take off camshaft sprocket. –  Unscrew toothed belt cover (rear). –  Remove cylinder head cover: left-side → Chapter, right-side → Chapter. –  Unplug electrical connector at camshaft adjuster. –  Remove Hall sender → Item and Hall sender rotor → Item. –  Turn the crankshaft approx. 45° anti-clockwise at the toothed belt sprocket bolt so that all pistons are clear of TDC position.

–  Check TDC position of camshafts again: l  The two marks on the camshafts must be opposite the two arrows on the bearing caps -arrows-.

If old drive chain is to be reused: –  Clean drive chain and sprockets of camshafts opposite the two arrows on the bearing caps and mark installation position with a coloured dot. l  The distance between the two arrows (and thus between the coloured markings) is 16 rollers on the chain. l  Notch on exhaust camshaft has a slight inward offset with respect to chain roller -1-.   Note Do not mark chain with a centre punch or by making a notch or similar.

Continued for all drive chains: –  Hold camshaft adjuster in position with chain tensioner retainer -3366-.   Note Over-tightening retainer for chain tensioner can damage the camshaft adjuster.

–  Mark the sequence and installation positions of all bearing caps, as shown, regardless of any existing markings on the bearing caps. –  Unscrew bolts securing camshaft adjuster -arrow-. –  Remove bearing cap -0-. –  Remove bearing caps -1-, -3- and -5- and place them in the correct order on a clean surface. –  Slacken off bearing caps -2- and -4- of inlet and exhaust camshafts alternately and diagonally, and remove. –  Lift out both camshafts with camshaft adjuster.

Installing Installation is carried out in the reverse order; note the following: –  Renew the semi-circular sealing plug. –  Renew rubber/metal gasket for camshaft adjuster and apply a thin coat of sealant to the -hatched area-; Sealant → Parts catalogue.

–  Position drive chain as follows on camshaft chain sprockets: If old drive chain is to be reused: l  Adjust the colour markings -arrows- so they are aligned. If new drive chain is being used:   Caution t  The stated number of rollers merely provides assistance for fitting the drive chain onto the camshafts. t  Make sure that the arrows on the bearing caps and the notches on the camshafts align when installing camshafts (with drive chain) in cylinder head → Anchor.

Cylinder head (left-side): l  The distance between notches -A- and -B- on the camshafts must be 16 drive chain rollers. The illustration shows the exact positions of the 1st and 16th rollers on the sprockets. l  The chain rollers -1- and -16- are offset 1/2 tooth outwards in relation to notches -A- and -B-

Cylinder head (right-side): l  The distance between notches -A- and -B- on the camshafts must be 16 drive chain rollers. The illustration shows the exact positions of the 1st and 16th rollers on the sprockets. l  The chain rollers -1- and -16- are located vertically above notches -A- and -B-. Continued for all drive chains: –  Insert camshaft adjuster into the chain (2nd mechanic required). –  Insert camshafts with drive chain and camshaft adjuster into cylinder head. –  Lubricate running surfaces of camshafts. l  Dowel sleeves for bearing caps and camshaft adjuster must be positioned in cylinder head

–  Secure camshaft adjuster -arrow- (watch position of dowel sleeves). –  Install bearing caps -2- and -4- as per marking. –  Tighten bearing caps -2- and -4- of inlet camshaft and exhaust camshaft alternately in diagonal sequence. –  Install the two bearing caps -1- next to the chain sprockets on the inlet and exhaust camshafts. –  Remove chain tensioner retainer -3366-.

–  Check correct setting of camshafts: l  The two marks on the camshafts must be opposite the two arrows on the bearing caps -arrows-.   Note If necessary, turn camshaft slightly backwards or forwards so that the two marks coincide.

–  Apply a small quantity of sealant to the -hatched area- of the double bearing cap and the outer bearing cap adjacent to the camshaft adjuster; Sealant → Parts catalogue. –  Install bearing cap (pay attention to dowel sleeves). –  Install remaining bearing caps (pay attention to dowel sleeves). –  Renew oil seals for inlet and exhaust camshaft → Chapter, → Chapter or → Chapter. –  Torque down remaining bearing caps. –  Turn the crankshaft approx. 45° clockwise back to TDC at the toothed belt sprocket bolt and secure crankshaft with locking pin. –  Install cylinder head cover: left-side → Chapter, right-side → Chapter. –  Install toothed belt (adjust valve timing) → Anchor. –  Install vibration damper → Chapter. –  Install poly V-belt → Chapter. –  Install viscous fan → Chapter. –  Install lock carrier with attachments → Rep. Gr.50. –  Install front bumper → Rep. Gr.63.   Note t  After installing camshafts, wait for approx. 30 minutes before starting engine. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons). t  After working on the valve gear, turn the engine carefully at least 2 rotations by hand to ensure that none of the valves make contact when the starter is operated. Tightening torques

Component	Nm
Bearing cap to cylinder head	10
Camshaft adjuster to cylinder head	10
Hall sender rotor to camshaft	25
Hall sender housing to cylinder head	10
Toothed belt cover (rear) to cylinder head/ cylinder block	10 1)
l  1) Install bolts using locking fluid; locking fluid → Parts catalogue.