Audi Workshop Service and Repair Manuals

Removing and installing camshafts, engine codes BYT, BPU Special tools and workshop equipment required

t  Puller -T40039-

t  Assembly tool -T10352- and assembly tool -T10352/1-

t  Counterhold tool -T10355-

t  Locking pin -T40011-

t  Thrust piece -T10174- Removing   Note t  Sealing surfaces at bottom of cylinder head cover and top of cylinder head must not be machined. t  The camshaft bearings are integrated into the cylinder head and cylinder head cover. The timing chain must be slackened before removing the cylinder head cover. t  Renew sealing cap → Item if cylinder head cover has been detached. t  Fit cable ties in the original positions when installing. Removing

–  Remove engine cover panel -arrows-.

–  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct at bottom together with air hose.

–  Unplug electrical connector -1- from air mass meter -G70-. –  Detach air intake hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.   Note Disregard item -3-.

–  Remove bolts -arrows-. –  Remove air pipe (lift clips -items 1 and 2-).

–  Detach air hoses -1, 2, 4, 5-. –  Unplug electrical connectors -3- at ignition coils and move wiring harness clear.

–  Remove ignition coils using puller -T40039-.

–  Remove filler cap -arrow-. –  Remove bolts -1 ... 6- and detach oil separator from cylinder head cover. –  Move vacuum line clear. –  Fit filler cap.

–  Detach connector from camshaft control valve 1 -N205--1-. –  Unscrew bolts -arrows- and remove camshaft control valve 1 -N205-.

–  Unscrew bolts -1 to 5- and remove timing chain cover (top).

Caution The timing valve has a left-hand thread. –  Depending on version, turn assembly tool -T10352- or assembly tool -T10352/1- in direction of -arrow- to remove timing valve.

–  Remove bolts -arrows- and detach bearing saddle.

–  Turn vibration damper to “TDC” position -arrow- using counterhold tool -T10355-. l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom).

–  Use a waterproof pen to mark drive chain according to markings on chain sprockets -arrows-.

–  Remove sealing plug -arrow-.

–  Insert scriber or suitable screwdriver in hole of chain tensioner in direction of -arrow 1- and lift locking element for chain tensioner. –  Turn crankshaft in opposite direction to normal rotation -arrow 2- and lock in place using locking pin -T40011-.   Note Inlet camshaft will move in direction of engine rotation.

–  Remove bolt -1- and detach tensioning rail -2- downwards. –  Use screwdriver to release catch and press off top guide rail -3- forwards. –  Remove camshaft timing chain from camshaft sprockets.   Caution Avoid damage to valves and piston crowns. Do not turn the crankshaft after the camshaft timing chain has been removed from the cylinder head.

–  Unplug connector -1- from Hall sender -G40-. –  Remove high-pressure pump → Rep. Gr.24. –  Remove exhauster pump → Rep. Gr.47.

–  Remove cylinder head cover bolts in the sequence -1 ... 6-. –  Detach cylinder head cover. –  Detach camshafts.   Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine. Installing l  Tightening torques → Chapter „Valve gear, engine codes BYT, BPU - exploded view“   Note t  The sealing surfaces must be free of oil and grease. t  Pistons must not be at TDC. t  Ensure that all roller rocker fingers contact the valve ends correctly. t  Silicone sealant → Electronic parts catalogue t  Note expiry date of silicone sealant. t  The cover must be installed within 5 minutes after applying the silicone sealant. –  Remove sealant remaining on cylinder head with flat scraper.   WARNING Protect eyes against injuries. Wear safety goggles.   Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine.

–  Remove sealant residue in groove of cylinder head cover and on sealing surfaces, e.g. using a rotating plastic brush. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 2 mm). –  Oil running surfaces of both camshafts.

–  Fit camshafts in cylinder head, recesses -arrows- must face each other. –  Renew bolts for cylinder head cover.

–  Apply silicone sealant onto clean sealing surface of cylinder head cover, as illustrated -arrows-. t  Thickness of sealant bead: 2 ... 3 mm.   Note t  The cylinder head cover must be installed within 5 minutes after applying the silicone sealant. t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe. t  Note the use-by date of the sealant. Sealant → Electronic parts catalogue –  Tighten bolts in several stages; tightening sequence → Fig..   Note Take care to keep cylinder head cover straight.

–  Use thrust piece -T10174- to drive in sealing cap -1- (do not apply sealant). -a- = 1 ... 2 mm

WARNING Make sure that components are not damaged by the timing chain when rotating the crankshaft. –  Turn vibration damper to “TDC” position -arrow- using counterhold tool -T10355-. l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom).   Note The timing chain links with markings must be positioned at the markings on the chain sprockets.

–  Fit timing chain: markings on chain/chain sprockets -arrows- must align. –  Use spanner to turn inlet camshaft in direction of -arrow- and fit timing chain.

–  Attach bearing saddle and screw in bolts -arrows- hand-tight. –  Remove locking pin -T40011-. –  Tighten bolts -arrows- for bearing saddle → Chapter. –  Install timing valve → Item. –  Install high-pressure pump → Rep. Gr.24. –  Install exhauster pump → Rep. Gr.47. Further assembly is basically carried out in reverse order of dismantling.