Audi Workshop Service and Repair Manuals

Removing and installing camshaft Special tools and workshop equipment required

t  Counterhold tool -3415- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue Removing l  Cylinder head installed.   Note t  Sealing surfaces at retaining frame and cylinder head may be cleaned but not machined. t  Camshaft bearings are integrated into cylinder head/retaining frame. Toothed belt must be detached before removing retaining frame. t  Renew camshaft oil seal and sealing cap at rear if retaining frame has been unfastened. –  Remove intake manifold → Rep. gr.24. –  Remove toothed belt from camshaft sprocket → Chapter.

–  Loosen camshaft sprocket using counterhold -3415-. –  Detach camshaft sprocket. –  Remove parallel key from camshaft. –  Remove cylinder head cover → Chapter.

–  Unbolt toothed belt cover (rear) from cylinder head -arrows-.

–  Unscrew nuts -1, 2, 7, 8, 9, 10-. –  Unscrew nuts -3, 4, 5, 6- in several stages and in diagonal sequence. –  Remove retaining frame. –  Remove camshaft. –  Ensure that the rocker fingers and the supporting elements are not interchanged. Installing   Note Renew gaskets and seals. l  Pistons must not be at TDC. l  Make sure dirt and remnants of sealant do not drop into cylinder head.

–  Remove old sealant from groove in retaining frame -arrow- and from sealing surfaces. –  Remove sealant residues from cylinder head, e.g. with rotating plastic brush or similar.   WARNING Wear safety goggles. –  Clean sealing surfaces; they must be free of oil and grease.   Note

Note the use-by date of the sealant. –  Cut off tube nozzle at front marking (diameter of nozzle approx. 1 mm).

–  Ensure all roller rocker fingers contact the valve ends -1- correctly and are clipped into their respective support elements -2-.

–  Lubricate running surfaces of the camshaft. –  Install camshaft in TDC position for cylinder 1: l  The cams for cylinder 1 must point upwards evenly on camshaft -arrows-.

–  Apply an even bead of sealant -1- and -2- onto the clean groove of the retaining frame (slightly projecting from the groove). –  Apply a thin coat of sealant onto the sealing surface in front of the ends of the beads of sealant -arrows-.   Note t  Do not apply the sealant thicker than prescribed. If necessary remove excess sealant with a lint-free cloth. t  No time should be allowed to elapse when fitting and securing retaining frame, as sealant starts to harden immediately. –  Insert rear sealing cap → Item so that it is flush.

–  Fit retaining frame and lightly tighten nuts -3, 4, 5, 6- diagonally in several stages. –  Then tighten nuts -1, 2, 7, 8, 9, 10- lightly. –  Finally tighten nuts to specified torque in the sequence -1 ... 10-. –  Install cylinder head cover → Chapter. –  Renew camshaft oil seal → Chapter. –  Install toothed belt (adjust valve timing) → Anchor.   Note t  After fitting retaining frame and cylinder head cover, allow sealant to dry for approx. 30 minutes. t  After installing the camshaft, the engine must NOT be started for about 30 minutes. 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 to ensure that none of the valves make contact when the starter is operated. Tightening torque

Component	Nm
Retaining frame to cylinder head	23