Audi Workshop Service and Repair Manuals

Removing and installing camshaft adjuster

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Shackle -10 -222 A /12-

t	Workshop hoist -VAS 6100- or -V.A.G 1202 A-

t	Pin wrench -T10020-

t	Tensioning bolt -T10092-

t	Camshaft clamp -T10252-

t  Mud wing compensation plate -T40045-

t  Special wrench, long reach -T40080- Removing   Note All cable ties which are released or cut open when removing must be fitted in the same position when installing.   WARNING The fuel system operates under high pressure. The pressure in the high-pressure part of the injection system must be reduced to a residual pressure prior to opening the system → Rep. Gr.24. A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection. –  Remove cylinder head cover → Chapter.

–  Pull off bonnet seal at wing mounting flanges. –  Place compensation plates -T40045- between the wing mounting flange and the body panel underneath, so that the support bracket -10-222 A- does not damage the wing mounting flanges.

–  Position support bracket -10-222 A- on wing mounting flanges (spindle faces to rear). –  Engage shackle -10-222 A/12- into rear engine lifting eye. –  Attach hook on spindle -10-222 A/11- to shackle. –  Take up weight of engine using spindle of support bracket.

–  On vehicles with auxiliary/additional heater, remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-fasteners -1- and -2- and take off front noise insulation.

–  Remove bolts -arrows-. –  Remove torque reaction support.

Vehicles up to 10.2004: –  If fitted, unclip actuator rod for vehicle level sender at bottom transverse link -arrow-.

Vehicles from 11.2004 onwards: –  If fitted, unplug electrical connector -arrow- at front left vehicle level sender -G78-.

All models: –  Remove bolts -1- and -2- from anti-roll bar mounting.

–  Cut open the cable ties -arrows-, open bracket for starter wire and take out the electrical wire.

–  Support subframe using workshop hoist -VAS 6100- or -V.A.G 1202 A-.   Note

To avoid having to check and adjust wheel alignment, only loosen the front subframe mountings and lower the subframe at the front. –  Unscrew nut -3- at bottom of engine mounting. –  Unscrew bolts -4- and -5- on console for engine mounting. –  Unscrew bolt -1- (front) for subframe and remove console for engine mounting -2-. –  Repeat procedure on other side of vehicle.

–  Carefully lower subframe using workshop hoist -VAS 6100- or -V.A.G 1202 A-.

–  Lower engine using spindle -10-222 A/11- of support bracket -10-222 A-. –  Ensure that hoses/pipes and wires are not stretched and that the selector linkage and exhaust system do not become trapped.

–  Unplug connector -item 1- for inlet camshaft control valve 1 -N205- and -item 4- for fuel pressure regulating valve -N276-. –  Remove inlet camshaft control valve 1 -N205--item 2-. –  Remove exhauster pump -3-.   Note Shown in illustration from rear with engine removed.

–  Remove banjo bolts -6- and -8- and detach fuel line. –  Remove bolts -2 ... 4-. –  Unscrew banjo bolts -1-, -5- and -7-. –  Move fuel lines to the side (hoses remain connected).   Note Shown in illustration with intake manifold removed.

–  Disconnect fuel return pipe at bulkhead -arrow-.

–  Unscrew bolts -arrows- and remove camshaft adjuster cover -A-.   Note Shown in illustration from rear with engine removed.

–  Remove centre securing bolt of chain tensioner -arrow-.

–  Secure chain tensioner with tensioning bolt -T10092- and nut (M5) -arrow-.   Caution The engine must only be turned at the crankshaft, in the direction of normal engine rotation (clockwise).

–  Rotate crankshaft to TDC by turning central bolt for toothed belt sprocket. l  Marking on camshaft sprocket and marking on crankshaft must be aligned to TDC -arrows-.

–  Insert camshaft clamp -T10252- as far as stop and tighten the bolts -arrows-.   Note If necessary, turn camshafts slightly backwards or forwards when inserting camshaft clamp -T10252-.

–  Unscrew camshaft adjuster bolt using special wrench (long reach) -T40080-. –  Remove camshaft adjuster together with drive chain from chain tensioner and camshafts.

Installing   Note t  Renew gaskets, seals and O-rings. t  Fit all cable ties in the original positions when installing. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. l  Camshafts locked in TDC position with camshaft clamp -T10252-. –  Position camshaft adjuster in front of exhaust camshaft so that notch -A- and pin -B- face each other.

–  Lay chain over inlet camshaft sprocket starting at top -arrow- without changing its position.

–  Turn inlet camshaft slowly in direction of arrow -A- using 2-hole pin wrench -T10020- until the camshaft adjuster fits onto the camshaft.   Note Repeat installation of the drive chain if the camshaft adjuster pin does not engage in the notch on the exhaust camshaft.

–  Tighten camshaft adjuster bolt using special wrench (long reach) -T40080-. –  Detach camshaft clamp -T10252-. –  Remove tensioning bolt -T10092-. Installation is carried out in the reverse order; note the following: –  Secure fuel lines → Rep. Gr.24. –  Install subframe → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install anti-roll bar → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.40. –  Install exhauster pump → Rep. Gr.47. –  Install cylinder head cover → Chapter. –  Install inlet camshaft control valve 1 -N205- → Anchor. Tightening torques

Component	Nm
Camshaft adjuster to camshaft	100
Chain tensioner to cylinder head	10 1)
Camshaft adjuster cover to cylinder head	10 1)
Console for engine mounting to longitudinal member	75
Engine mounting to console for engine mounting	23
Torque reaction support to sump	23
l  1) Install using locking fluid; for locking fluid refer to → Parts catalogue.