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: t  Vehicles up to approx. 05.2005 → Chapter t  Vehicles from approx. 06.2005 → Chapter

–  Unplug electrical connector -2- at air mass meter -G70-. –  Detach vent hose -1- and air hoses -3- and -5-. –  Unscrew bolt -4- and remove air cleaner housing. –  Remove tandem pump → Rep. Gr.20.   Note The hoses can remain attached to the tandem pump.

–  Remove locking pin -3359-. –  Unscrew bolts -arrows- for camshaft sprocket and remove camshaft sprocket from hub.

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

–  Apply puller -T10052- and screw bolts -1- into hub. –  Remove hub by screwing in bolt -2- while counterholding at hexagon flats (30 mm) of puller. –  Remove cylinder head cover → Chapter.

–  Mark rocker arm shafts with waterproof felt pen to make sure that they are reinstalled in the previous position and to avoid performing a basic setting of the unit injectors -arrows-. –  First loosen the two outer bolts -1- on the rocker arm shafts, then the inner bolts -2-. –  Remove the rocker arm shafts.

–  First remove the bearing caps -1-, -3- and -5-. –  Then loosen bearing caps -2- and -4- alternately in diagonal sequence.   Note 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  Crankshaft sprocket is locked using crankshaft stop -T10050- for engines with circular crankshaft sprocket, or crankshaft stop -T10100- for engines with oval crankshaft sprocket.   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-.   Note

If the bearing caps are fitted with the cylinder head removed, the washers for the cylinder head bolts → Item must first be fitted. –  Tighten bearing caps -2- and -4- alternately in diagonal sequence.

–  Apply a thin and even coat of sealant to surfaces -1- of bearing caps 1 and 5; sealant → Parts catalogue.   Note Make sure no sealant gets into the grooves -arrows- or onto the other surfaces.

–  Install bearing caps -1-, -3- and -5- and tighten. l  Bearing cap 5 must be flush with the outer edge of the cylinder head, otherwise the tandem pump may leak. –  Install camshaft oil seal → Anchor.

–  Before installing rocker arm shaft, check that all ball studs -2- and O-rings -1- are fitted in unit injectors.

–  Install rocker arm shafts. When doing so, note the markings made on removal -arrows-. –  First tighten inner bolts -2- and then outer bolts -1- 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-. –  Fit toothed belt (adjust valve timing): t  Vehicles up to approx. 05.2005 → Anchor t  Vehicles from approx. 06.2005 → Anchor –  Install tandem pump → Rep. Gr.20. –  If the rocker arm shafts or ball studs and adjuster screws were renewed, the unit injectors must be adjusted → Rep. Gr.23. –  Install cylinder head cover → Anchor.   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.