Audi Workshop Service and Repair Manuals

Removing and installing camshafts Special tools and workshop equipment required t  Sealant → Parts catalogue

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

–  Open quick-release fasteners -1 … 3- and take off front and rear noise insulation. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50.

–  Detach toothed belt from camshaft sprockets → Chapter. –  Take off camshaft sprocket (right-side). –  Remove cylinder head cover: left-side → Chapter, right-side → Chapter. –  Lift off centre section of rear toothed belt cover -2-. –  Unscrew bolts -arrows- and detach rear left toothed belt cover -3- or rear right toothed belt cover -1-.

–  Remove retainers of injectors on relevant side -arrows- and pull out injectors upwards. –  Use waterproof felt-tip pen to mark installation position of rocker fingers. –  Unscrew camshaft bearing caps in stages and in diagonal sequence. –  Remove camshafts.   Note Pay attention to rocker fingers and guides when detaching camshafts.

Installing   Note Renew seals for cap nuts. l  Crankshaft locked in position with locking pin -3242-. –  Unscrew stud -arrow- in front of securing slot in exhaust camshaft. –  Insert thrust washers. –  Insert rocker finger guides and rocker fingers (note marking).   Note t  Pay attention to correct positioning of rocker finger guides. t  Apply a small quantity of grease to facilitate installation of rocker fingers and rocker finger guides (if necessary).

–  Install inlet camshaft so that the camshaft clamp -3458- can be inserted.

–  Ensure correct positioning (note offset). Before installing camshafts, fit bearing caps and determine correct position for installation.

–  Tighten bearing caps -1- and -5-.   Note Pay attention to numbering on bearing caps.

–  Install exhaust camshaft so that the camshaft clamp -3458- can be inserted.

–  Tighten bearing caps -0- and -4-. –  Re-check setting with camshaft clamp -3458-. –  Check installation position of rocker fingers and guides.

–  Remove any traces of remaining sealant from cylinder head and camshaft bearing caps. –  Clean contact surfaces between cylinder head and bearing caps; surfaces must be free from oil and grease. –  Apply a small quantity of sealant to -hatched areas- of outer bearing cap at front left/rear right.

–  Apply a small quantity of sealant to -hatched areas- of outer bearing cap at rear left/front right.   Note Sealant must not be allowed to come into contact with -grey-shaded areas- shown in illustration. –  Fit outer bearing caps. –  Torque down remaining bearing caps. –  Fit stud.   Note Renew copper seal and O-ring between cylinder head and injectors. –  Make sure injectors are properly positioned. –  Tighten retainers. Remaining installation steps are carried out in reverse sequence; note the following: –  Renew camshaft oil seal → Chapter. –  Install cylinder head cover: left-side → Chapter, right-side → Chapter. –  Install toothed belt (adjust valve timing) → Anchor. –  Install viscous fan → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63.   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 to ensure that none of the valves make contact when the starter is operated. Tightening torques

Component		Nm
Bearing cap to cylinder head	Cap nuts	15 → Note
	Hexagon nuts	10
	Hexagon bolts	10
Stud in cylinder head		5
Injectors in cylinder head		10

1)  Renew seals when fitting