Audi Workshop Service and Repair Manuals

Removing and installing camshaft Special tools and workshop equipment required

t  Counterhold tool -T10051-

t  Puller -T10052- t  Sealant → Parts catalogue

Removing l  Cylinder head installed. –  Remove toothed belt: toothed belt drive with hydraulically damped tensioning roller → Chapter, toothed belt drive with friction-damped tensioning roller → Chapter. –  Remove locking pin -3359-. –  Unscrew bolts -1- and detach camshaft sprocket from hub.

–  Loosen bolt -1- for hub; use counterhold tool -T10051-. –  Then unscrew bolt approx. 2 turns.

–  Fit puller -T10052- on hub and fit bolts -1-. –  Remove hub from camshaft by screwing in bolt -2- while counterholding at hexagon flats (30 mm) of puller. –  Detach hub from taper of camshaft. –  Remove cylinder head cover → Chapter. –  First loosen outer bolts on rocker arm shaft, then inner bolts and remove rocker arm shaft. –  Remove tandem pump → Rep. Gr.20. –  First remove bearing caps “2” and “3”. –  Then loosen bearing caps “1” and “4” alternately in diagonal sequence.   Note t  Bearing cap “4” is marked as bearing cap “5”. t  Make sure that the camshaft bearing shells are not interchanged. t  Mark allocation of camshaft bearing shells on rear with a waterproof felt-tip pen. –  Remove camshaft.

Installing Installation is carried out in the reverse order; note the following: l  The crankshaft sprocket must be locked with the crankshaft stop -T10050-. l  The markings on the toothed belt sprocket and the crankshaft stop -arrow- must align. The pin of the crankshaft stop must engage in the aperture in the sealing flange.   Note t  Make sure that the used camshaft bearing shells are not interchanged (note marking). 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 contact surfaces of camshaft. –  Install camshaft in “TDC” position for cylinder 1: l  The cams for cylinder 1 must point upwards on camshaft -arrows-. –  Tighten bearing caps “2” and “3” alternately in diagonal sequence.

–  Apply a thin and even coat of sealant to surfaces -1- on bearing caps “1” and “4”; for sealant refer to → Parts catalogue.   Note t  Bearing cap “4” is marked as bearing cap “5”. t  Make sure no sealant gets into the grooves -arrows- or onto the other surfaces. –  Install bearing caps “1” and “4” and tighten. l  Bearing cap “4” must be flush with the outer edge of the cylinder head, otherwise the tandem pump may leak. –  Install camshaft oil seal → Anchor. –  Fit rocker arm shaft, then first tighten inner bolts then outer bolts in several stages.

–  Attach hub to camshaft. –  Tighten securing bolt -1- (use counterhold -T10051-).

–  Push camshaft sprocket onto hub. l  Toothed segment -arrow- in camshaft sprocket must face upwards. –  Screw in bolts -1- finger-tight. –  Lock hub on camshaft with locking pin -3359-. –  Install toothed belt (adjust valve timing): toothed belt drive with hydraulically damped tensioning roller → Anchor, toothed belt drive with friction-damped tensioning roller → Anchor. –  Install tandem pump → Rep. Gr.20. –  If the rocker arm shaft or ball studs and adjuster screws were renewed, the unit injectors must be adjusted → Rep. Gr.23. –  Install cylinder head cover → Chapter.   Note t  After installing the camshaft, the engine must NOT be started for about 30 minutes. 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 cap to cylinder head	8 + 90° 1)2)
Rocker arm shaft to cylinder head	20 + 90° 1)2)
Hub to camshaft	100
l  1) Renew bolts. l  2) 90° = one quarter turn.