Audi Workshop Service and Repair Manuals

Removing and installing camshafts and camshaft adjuster Special tools and workshop equipment required

t  Puller -T10055-

t  Assembly tool -T10029- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Parts catalogue Removing –  Remove toothed belt → Chapter. –  Remove camshaft sprockets on respective cylinder head. –  Remove combination valve for secondary air system: left-side → Chapter, right-side → Chapter.

Cylinder head (right-side): –  Unplug electrical connector at Hall sender -G40--item 1- and at Hall sender 3 -G300--item 2-.

–  Remove bolts -1- and take off bracket with idler roller. –  Remove bolts -2- and take off toothed belt cover (rear right).

Cylinder head (left-side): –  Remove bolts -1- and -2- and take off toothed belt cover (rear left).

Continuation for both sides: –  Remove camshaft clamp -T40030- from camshafts. –  Unscrew bolts -1 ... 6- and remove housing for camshaft control valves.

–  Unscrew bolts -1 ... 6- and take off housing for Hall sender.

–  Loosen bolts on retaining frame in the sequence shown by the numbers and then following the arrows.

–  Press off retaining frame using M6 bolts -arrows-. –  Carefully remove retaining frame. –  Take out camshafts. Installing   Note Renew gaskets and seals. l  Crankshaft locked in position with locking pin -T40026-.   WARNING Wear safety goggles. –  Remove sealant residue from cylinder head and retaining frame using a rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease. –  Lubricate running surfaces of camshafts.

Cylinder head (left-side): –  Position camshafts in cylinder head as illustrated. l  The cams of No. 5 cylinder point downwards at equal angles -arrows-.

Cylinder head (right-side): –  Position camshaft in cylinder head as illustrated. l  The cams of No. 3 cylinder point upwards at equal angles -arrows-.

Continuation for both sides: –  Cut off tube nozzle at front marking (nozzle approx. 1 mm Ø).

–  Apply sealant bead to clean sealing surface of retaining frame, as shown in illustration. l  The bead of sealant should be approx. 1.2 mm wide. l  The sealant bead must be at least 5 mm away from the camshaft bearings at the points -1 ... 8- in the illustration. l  Additionally apply a ring of sealant to the sealing surface around each spark plug hole -9 ... 11-.   Note t  The bead of sealant must be applied exactly according to these instructions, otherwise excess sealant can get into the camshaft bearings. t  The retaining frame must be installed within 5 minutes after applying sealant.

–  Fit retaining frame immediately and locate in position using locking pin -T40029-.   Note After installing the retaining frame, wait about 30 minutes for the sealant to dry.

–  To start with, tighten bolts on retaining frame hand-tight: tighten uniformly in the sequence shown by the numbers, and then following the arrows. l  The retaining frame should make contact with the cylinder head over the full surface. –  Tighten bolts securing retaining frame to final torque (10 Nm).

–  Pull mandrel -T40029- out of cylinder head and retaining frame using puller -T10055-.

Cylinder head (left-side): –  Attach camshaft clamp -T40030- to camshafts. –  Expand camshaft clamp -T40030- by means of the threaded spindle (tightening torque max. 10 Nm) until it is seated with zero play.

Cylinder head (right-side): –  Install camshaft sprocket on exhaust camshaft. –  Rotate exhaust camshaft -arrow 1- and inlet camshaft -arrow 2- 30° in direction of -arrows-.

–  The cams -arrows- at No. 3 cylinder on inlet and exhaust camshafts must be positioned as shown in illustration.

–  Attach camshaft clamp -T40030- to camshafts. –  Remove camshaft sprocket from exhaust camshaft again.

Continuation for both sides: –  Install housing for Hall sender and tighten bolts -1 ... 6-.   Note

t  Depending on version, the piston rings on the camshaft adjusters are supplied with lugs at the ends. t  Hook ends of piston rings together on this version.

–  If necessary, hook ends of piston rings -arrows- together as illustrated.   Note

t  If camshaft oil seals are being renewed, they must be pried out using lever -T40017- before installing housing for camshaft control valves. t  Installing camshaft oil seals → Chapter.

–  Install housing for camshaft control valves and tighten bolts -1 ... 6-. Remaining installation steps are carried out in reverse sequence; note the following: –  Install combination valve for secondary air system: left-side → Chapter, right-side → Chapter. –  Install toothed belt (adjust valve timing) → Anchor.   Note 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 by hand to ensure that none of the valves make contact when the starter is operated. Tightening torques

Component	Nm
Retaining frame to cylinder head	10
Hall sender housing to cylinder head	10
Housing for camshaft control valves to cylinder head	10
Toothed belt cover (rear) to cylinder head/ cylinder block	10 1)
l  1) Renew bolts.