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 → Parts catalogue Removing   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 toothed belt from camshaft sprocket → Chapter. –  Loosen camshaft sprocket using counterhold -3415-. –  Detach camshaft sprocket. –  Remove parallel key from camshaft.

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

–  Remove crankcase breather hose from cylinder head cover. –  Unscrew cylinder head cover bolts in the sequence -8 ... 1-. –  Remove cylinder head cover.

–  Unscrew nuts -1-, -2-, -7-, -8-, -9- and -10-. –  Unscrew nuts -3-, -4-, -5- and -6- in several stages and in diagonal sequence. –  Remove retaining frame. –  Remove camshaft. 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.

–  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø).

–  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- and -6- diagonally in several stages. –  Then tighten nuts -1-, -2-, -7-, -8-, -9- and -10- slightly. –  Finally tighten nuts to specified torque in the sequence -1 ... 10-. –  Install cylinder head cover → Anchor. –  Renew camshaft oil seal → Chapter.

–  Install toothed belt cover (rear) -arrows-. –  Insert parallel key into camshaft.   Caution If a piston is at TDC the valves could strike the piston when turning the camshaft. Pistons must therefore not be at TDC This could otherwise result in damage to valves and pistons. –  Tighten camshaft sprocket using counterhold -3415-.

–  –  Fit 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, wait for about 30 minutes before starting the 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. Tightening torques

Component	Nm
Retaining frame to cylinder head	23
Camshaft sprocket to camshaft	100