Audi Workshop Service and Repair Manuals

Removing camshafts and re-installing used camshafts - cylinder bank 1 (right-side) Special tools and workshop equipment required

t  Counterhold tool -T10172- with adapter -T10172/5-

t  Adjustment pin -T40060-

t  Camshaft fitting tool -T40096-

Removing –  Remove timing chain from inlet camshaft → Chapter. l  Crankshaft -1- locked in „TDC“ position with locking pin -3242-.

–  Check „TDC“ position of camshafts: l  It should be possible to lock the inlet camshaft -1- with the adjustment pin -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. l  Exhaust camshaft -2- must be set so that groove -arrow B- is parallel above joint -arrow A- between bearing pedestal and bearing cap.

–  Place camshaft fitting tool -T40096- on teeth of inlet camshaft so that the two arms of the tool engage on the two halves of the gear (one in each half, as shown in illustration). l  The wider arm must engage in the wider half of the gear. –  Tighten the clamping tool using the knurled wheel so that the faces of the gear teeth are in alignment.

–  Wrap one cable tie -arrows- on each side around bearing pedestal and bearing cap and secure.   Note With the cable ties it is possible to detach the camshafts together with the camshaft bearings; this prevents components from being interchanged.

–  Pull off adjustment pin -T40060-. –  Screw two bolts for camshaft chain sprocket five turns into threaded holes in camshaft, as shown in illustration.

–  Fit counterhold tool -T10172- with adapter -T10172/5- on both bolts and turn camshafts approx. 30° in anti-clockwise direction -arrow- until groove -arrow A- in camshaft points vertically to sealing surface -arrows B- of cylinder head.   Caution Risk of damage to valves. Do not turn camshafts any further than specified.

–  Loosen bearing cap bolts in the sequence -12 ... 1-.   Note Make sure you do not damage the roller rocker fingers and hydraulic compensation elements when removing the camshafts. –  Carefully detach bearing caps together with camshafts.   Caution Do NOT interchange components! Do not release cable ties until after re-installation.

Installing l  Tightening torques → Chapter „Valve gear - exploded view“ l  Crankshaft locked in „TDC“ position with locking pin -3242-. –  Place camshaft fitting tool -T40096- on teeth of inlet camshaft so that the two arms of the tool engage on the two halves of the gear (one in each half, as shown in illustration). l  The wider arm must engage in the wider half of the gear. –  Tighten the clamping tool using the knurled wheel so that the faces of the gear teeth are in alignment.

–  Fit camshafts and camshaft bearings (secured with cable ties -arrows-) on cylinder head.   Note The cable ties help to keep the camshafts and camshaft bearings straight when they are tightened.

–  Check „TDC“ position of camshafts: l  It should be possible to lock the inlet camshaft -1- with the adjustment pin -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. l  Exhaust camshaft -2- must be set so that groove -arrow A- is parallel above joint -arrow B- between bearing pedestal and bearing cap.

–  Pull off adjustment pin -T40060-. –  Screw two bolts for camshaft chain sprocket five turns into threaded holes in camshaft, as shown in illustration.

–  Fit counterhold tool -T10172- with adapter -T10172/5- on both bolts and turn camshafts approx. 30° in anti-clockwise direction -arrow- until groove -arrow A- in camshaft points vertically to sealing surface -arrows B- of cylinder head.   Caution Risk of damage to valves. Do not turn camshafts any further than specified.

–  Check installation position of dowel sleeves: l  Both dowel sleeves -arrows- must be inserted in holes in bearing pedestal „IV“. l  Dowel sleeves must engage in holes in cylinder head.

–  Tighten bearing cap bolts → Fig..

–  Fit counterhold tool -T10172- with adapter -T10172/5- on both bolts and turn camshafts approx. 30° in clockwise direction -arrow- until groove -arrow A- in camshaft is aligned with hole -arrow B- for adjustment pin -T40060-.

–  Check „TDC“ position of camshafts: l  It should be possible to lock the inlet camshaft -1- with the adjustment pin -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. l  Exhaust camshaft -2- must be set so that groove -arrow A- is parallel above joint -arrow B- between bearing pedestal and bearing cap. Remaining installation steps are carried out in reverse sequence; note the following: –  Remove camshaft fitting tool -T40096-. –  Install camshaft timing chains → Chapter.   Caution Avoid damage to valves and piston crowns after working on valve gear. t  The hydraulic tappets have to settle; wait for approx. 30 minutes after installing camshafts before starting engine. t  Turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.