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 → Electronic parts catalogue

Removing –  Vehicles with auxiliary 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. Leave rear noise insulation in position. –  Remove bumper cover (front) → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50.

–  Remove toothed belt: t  Vehicles with hydraulically damped tensioning roller - engine codes AVB, AVF, AWX → Chapter. t  Vehicles with friction-damped tensioning roller - engine codes AVB, AVF, AWX → Chapter. t  Engine codes BKE, BPW, BRB, BRC → Chapter. –  Remove camshaft sprocket securing bolts -1-. –  Detach camshaft sprocket from hub.

–  Loosen securing bolt -1- for hub; use counterhold tool -T10051-. –  Then unscrew bolt approx. 2 turns.

–  Apply puller -T10052- and align it with holes in hub. –  Screw bolts -1- into hub. –  Apply tension to hub by evenly tightening centre bolt -2- until hub separates from taper of camshaft.   Note Use 30 mm spanner to hold puller. –  Detach hub from taper of camshaft.

–  Detach crankcase breather hose at pressure control valve -arrow-. –  Unscrew cylinder head cover bolts in the sequence -13 ... 1- and remove cylinder head cover.

–  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 outer bolts -1- and then inner bolts -2- on both rocker arm shafts. –  Remove the rocker arm shafts. –  Remove tandem pump → Rep. Gr.20.   Note The fuel hoses can remain connected.

–  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   Note Renew the bolts tightened with specified tightening angle. l  The crankshaft sprocket must be locked in position: A -  For engine codes AVB, AVF, AWX: with crankshaft stop -T10050- B -  For engine codes BKE, BPW, BRB, BRC: with crankshaft stop -T10100-   Note t  The markings on the toothed belt sprocket and the crankshaft stop -arrow- must align. The pin of the crankshaft stop must engage in the aperture in the sealing flange. 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: l  The cams for cylinder 1 must point upwards evenly 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; for sealant refer to → Electronic 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 → Chapter.

–  Before inserting rocker arm shaft, check whether all ball studs -2- and O-rings -1- have been installed in unit injectors.

–  Install rocker arm shafts. When doing so, note the markings made on removal -arrows-. –  Tighten bolts on each section (I and II) as follows: first tighten inner bolts -2- and then outer bolts -1-.

–  Attach hub to camshaft. –  Tighten securing bolt -1- (use counterhold -T10051-).

–  Push camshaft sprocket onto hub. l  Toothed segment -arrow- of camshaft sprocket must be at top. –  Screw in bolts -1- finger-tight. –  Lock hub with locking pin -3359-. The remaining installation steps are carried out in the reverse sequence. –  Fit toothed belt (adjust valve timing): t  Vehicles with hydraulically damped tensioning roller - engine codes AVB, AVF, AWX → Anchor. t  Vehicles with friction-damped tensioning roller - engine codes AVB, AVF, AWX → Anchor. t  Engine codes BKE, BPW, BRB, BRC → 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. –  Install lock carrier with attachments → Rep. Gr.50. –  Install bumper cover (front) → Rep. Gr.63.   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.