Audi Workshop Service and Repair Manuals

Renewing exhaust camshaft oil seal

Special tools and workshop equipment required

t	Oil seal extractor -2085-

t	Adapter -2085/2-

t	Counterhold tool -3036-

t	Assembly tool -T10071-

t	Two-arm puller -T40001- with claw -T40001/6- and claw -T40001/7-

t	Torque wrench -V.A.G 1332-

Removing Cylinder head installed Engine code BLX, BLY, BLR, BVY, BVZ –  Remove toothed belt → Chapter. Engine code AXW, BMB, BHD

–  Lift off engine cover panel -arrows-.

–  Remove noise insulation (centre) - fasteners -1 ... 3-.

–  Remove noise insulation (right-side) - fasteners -1 ... 3-   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection. –  Mark fuel supply and return lines.

–  Detach hose going to activated charcoal filter -1-. –  Disconnect fuel supply line -2- by pulling release tab. –  Disconnect fuel return line -3- by pulling release tab.

–  Disconnect vacuum line -1- going to activated charcoal filter by pressing release tab. –  Disconnect fuel supply line -2- by pulling release tab. –  Disconnect fuel return line -3- by pulling release tab.

–  Lift out activated charcoal filter from retainer with pipes connected -arrow-.

–  Unbolt bracket -3- for ACF. –  Unfasten bolt at filler neck of washer fluid reservoir -2-. –  Disconnect electrical wire for coolant shortage indicator switch at expansion tank -1-. –  Unbolt coolant expansion tank and lay it aside with pipes connected.   Note Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

–  To slacken poly V-belt, turn tensioner in direction of -arrow-.

–  Lock tensioner in position with locking pin -T10060A-. –  Take off poly V-belt. –  Remove locking pin -T10060A- from tensioner for poly V-belt.

–  Remove the bolts -arrows- and lift off toothed belt cover.   Note Engage carefully in toothed belt cover (centre) when installing.   WARNING The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).   Note Apply spanner to central bolt of crankshaft for turning engine.

–  Rotate engine to TDC of No. 1 cylinder by turning central bolt of crankshaft sprocket in normal direction of rotation. Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC of cylinder No. 1 -arrows-.

–  Position support bracket -10 - 222 A- on bolted flanges of wing panels. The spindles face forwards. –  Detach crankcase breather hose from oil filler neck. –  Attach hooks of spindles with shackles -10 - 222 A /12- to the lifting eyes. –  Take up weight of engine evenly with both spindles (but do not raise engine).

–  Remove bolts -1- and -2- and detach connecting bracket. –  Remove bolts -3 ... 6- and detach engine mounting.

–  Remove bolts -arrows- and take off engine support   Note To slacken the bolts for the engine support, raise or lower the engine slightly as necessary via the spindles on engine support bracket -10 - 222 A-.

–  Unscrew bolts for toothed belt cover (centre) -arrows- and remove toothed belt cover from engine.

–  Loosen nut on tensioning roller -arrow- several turns. –  Remove toothed belt. All vehicles (continued):

–  Loosen camshaft sprocket (apply counterhold tool -3036-).

–  Detach the camshaft sprocket using puller -T40001- and claws T40001/6 and T40001/7.

–  To guide oil seal extractor, screw special tool 2085/2 from oil seal extractor -2085- by hand into camshaft as far as it will go. –  Unscrew inner part of oil seal extractor -2085- two turns (approx. 3 mm) from the outer part and lock in position with the knurled screw.

–  Lubricate threaded head of oil seal extractor -2085-, place it in position and, while exerting firm pressure, screw it into oil seal as far as possible. –  Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted. –  Clamp flats of oil seal extractor in vice. Remove oil seal with pliers. Installing Tightening torques → Chapter –  Do not lubricate sealing lip of oil seal.

–  Fit guide sleeve -T10071/1- from assembly tool -T10071- onto end of camshaft. –  Push oil seal over guide sleeve onto shaft. –  Detach guide sleeve.

–  Press oil seal in onto stop using press sleeve -T10071/3- and bolt -T10071/4- from assembly tool -T10071-.

–  Install camshaft sprocket. t  Check installation position: The thinner web of the camshaft sprocket faces outwards -arrows- and the marking for No. 1 cylinder TDC is visible.

–  Fit securing bolt of camshaft sprocket (use counterhold -3036-).   Note If a piston is at TDC the valves could strike the piston when turning the camshaft. Pistons must therefore not be at TDC This could otherwise result in damage to valves and pistons. –  Install toothed belt: engine codes AXW, BMB, BHD → Chapter, engine codes BLX, BLY, BLR, BVY, BVZ → Chapter.