Audi Workshop Service and Repair Manuals

Removing and installing camshafts - cylinder head (right-side)

Special tools and workshop equipment required

t	Puller -T10320- for vehicles from 09.2005 onwards

t	Camshaft fitting tool -T40094-

t	Camshaft fitting tool -T40095-

t	Camshaft fitting tool -T40096-

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Electronic parts catalogue

Removing –  Remove camshaft timing chain (right-side) from camshafts → Chapter. –  Remove cylinder head cover (right-side) → Chapter.

–  Unscrew retaining frame bolts and nuts in the sequence -17 ... 1-.   Note Make sure you do not damage roller rocker fingers and compensation elements when removing camshafts. –  Carefully remove retaining frame and camshafts. Installing   Caution The camshafts MUST be installed using the camshaft fitting tool -T40094- as described in the following, as the thrust bearings in the retaining frame would otherwise be destroyed. The cylinder head would then have to be renewed.   WARNING Wear safety goggles. –  Remove remaining sealant from cylinder head and retaining frame using rotating plastic brush or similar.   Caution Make sure that no sealant residue gets into the cylinder head or the bearings. –  Clean sealing surfaces; they must be free of oil and grease. –  Lubricate running surfaces of camshafts.

Set up camshaft fitting tool -T40094- as follows: –  Insert support -T40094/2- in position -B-. –  Insert support -T40094/1- in position -C-.

–  Place exhaust camshaft -1- in supports -T40094/1- and -T40094/2-. –  Turn exhaust camshaft in such a way that it can be locked in „TDC“ position using locking device -arrow-.

–  Place inlet camshaft -2- in camshaft fitting tool -T40094-. l  The locating bar -3- must engage in the groove on the inlet camshaft. –  Place camshaft fitting tool -T40096- on teeth of inlet camshaft in such a way that the two arms of the tool engage on the two halves of the gear (one in each half, as shown in illustration). –  Tighten the clamping tool using the knurled wheel so that the faces of the gear teeth are in alignment. –  Slide exhaust camshaft -1- towards inlet camshaft -arrows- until gear teeth engage.

–  Check that camshafts are in correct position: l  Recesses -arrows- on both camshafts must point outwards.

–  Fit retaining frame -1- on both camshafts. l  All camshaft bearings must be seated on the camshafts. –  Attach camshaft fitting tool -T40095- to camshafts (align arms of bracket as required and tighten knurled nuts -2-). –  Apply tension to camshafts by tightening the knurled nuts -3- upwards.

–  Check if dowel pins -arrows- are fitted in cylinder head. Install missing dowel pins.   Note

Note the use-by date of the sealant. –  Cut off nozzle of tube at front marking (nozzle Ø approx. 1.5 mm).   Note

For illustration purposes, the retaining frame is shown without the camshafts. –  Turn retaining frame upside down.   Caution Make sure lubrication system is not clogged by excess sealant. The sealant beads must not be thicker than specified. –  Apply beads of sealant -arrows- onto clean sealing surfaces of retaining frame as shown in illustration. l  The grooves on the sealing surface must be completely filled with sealant. l  The beads of sealant must project 1.5 … 2.0 mm above the sealing surface.   Note The retaining frame must be installed within 5 minutes after applying the sealant.   Caution Risk of damage to engine. Ensure that all roller rocker fingers contact the valve ends and compensation elements correctly.

–  Fit retaining frame together with both camshafts and camshaft fitting tool -T40095- onto cylinder head. –  Tighten bolts for retaining frame → Fig.. –  Remove camshaft fitting tool -T40095- and -T40096-. Remaining installation steps are carried out in reverse sequence; note the following:   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. –  Install cylinder head cover (right-side) → Chapter. –  Renew sealing cap (front) on cylinder head. –  Using a suitable drift, knock in new sealing cap (core plug) until flush. –  Install camshaft timing chain → Anchor. Tightening torque

Component	Nm
Retaining frame to cylinder head	9