Audi Workshop Service and Repair Manuals

Removing and installing camshafts Special tools and workshop equipment required

t  Camshaft bar -T10068 A- t  Lubricating paste → Electronic parts catalogue Removing l  Engine in vehicle.   Note t  All cable ties which are released or cut open when removing must be refitted in the same position when installing. t  Heat insulation sleeves that have been removed are to be reinstalled in the original position. –  Remove timing chain from camshafts → Chapter.

–  Unbolt the valve timing housing -arrows-. –  Carefully detach the valve timing housing from the oil seals for the camshafts.

–  Remove the inlet camshaft -A- as follows: 1 -  Unbolt bearing caps 1 and 13. 2 -  Unbolt bearing caps 3 and 11. 3 -  Unbolt bearing cap 7. 4 -  Loosen bearing caps 5 and 9 alternately in a diagonal sequence and remove. –  Remove the exhaust camshaft -B- as follows: 1 -  Unbolt bearing caps 2 and 14. 2 -  Unbolt bearing caps 4 and 12. 3 -  Unbolt bearing cap 8. 4 -  Loosen bearing caps 6 and 10 alternately in a diagonal sequence and remove. –  Carefully remove the camshafts and place them down on a clean surface. Installing l  Tightening torques → Chapter, → Fig..   Note t  The crankshaft must not be at TDC at any cylinder when the camshafts are installed. Otherwise, there is a risk of damage to valves and piston crowns. t  After installing camshafts, wait for approx. 30 minutes before starting engine. 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.

–  Fit hydraulic compensation elements in cylinder head. –  Fit roller rocker fingers -1- onto ends of valve stems and clip onto hydraulic compensation elements -2-. –  Lubricate running surfaces of camshafts.

–  Insert the respective camshaft in the camshaft bearings of cylinder head. –  Pay attention to the camshaft identification located between the cam pairs for cylinder No. 4 and 5: A -  Exhaust camshaft; identification 022 - index 101 B -  Inlet camshaft; identification 022 - index 102

–  Position camshafts in cylinder head so that cams -A- of cylinder 1 face each other.

–  Note the installation position of the bearing caps: l  The pointed section -arrow A- of the bearing caps for inlet and exhaust camshafts faces outwards. l  The identification markings for the bearing caps are legible from the inlet side.

–  Thinly coat contact surface -(hatched surface in illustration)- of bearing caps 7 and 8 with lubricating paste → Electronic parts catalogue.

–  Install the inlet camshaft -A- as follows: 1 -  Tighten bearing caps 5 and 9 alternately in diagonal sequence and then tighten to final torque. 2 -  Tighten bearing caps 1 and 13. 3 -  Tighten bearing cap 7. 4 -  Tighten bearing caps 3 and 11. –  Install the exhaust camshaft -B- as follows: 1 -  Tighten bearing caps 6 and 10 alternately in diagonal sequence and then tighten to final torque. 2 -  Tighten bearing caps 2 and 14. 3 -  Tighten bearing cap 8. 4 -  Tighten bearing caps 4 and 12.

–  Position the camshafts in cylinder head to TDC. l  You should be able to insert the camshaft bar -T10068 A- in the slots in both camshafts.

–  If necessary, turn camshafts at hexagon flats -arrows- to correct position using a 32 mm open-end spanner.   Note The crankshaft must not be at TDC at any cylinder when the camshafts are turned. Otherwise, there is a risk of damage to valves and piston crowns.

–  Unclip the filter -2- on the back of valve timing housing -1- and clean away any dirt or grime. –  Lightly oil the contact surfaces for the camshaft oil seals in the valve timing housing. –  Lightly oil contact surfaces of oil seals on the camshafts and carefully push the valve timing housing over the camshaft oil seals.

–  Tighten the valve timing housing -arrows-. –  Install camshaft timing chain (adjust valve timing) → Anchor. 1)  45° equals 1/8 of a turn.