Audi Workshop Service and Repair Manuals

Removing and installing camshafts

Special tools and workshop equipment required

t	Impact extractor attachment -T10133/3- from tool set for FSI engines -T10133-

t	Locking pin -T40069-

t	Camshaft clamp -T40070- (2x)

t	Locating pins 1 set = 2x -T40116-

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Electronic parts catalogue

Removing –  Remove cylinder head cover: left-side → Chapter, right-side → Chapter. –  Remove timing chain covers (left and right) → Chapter. –  Detach timing chains from camshafts → Chapter. –  To remove the camshafts (right-side) you must first remove the exhauster pump for brake servo → Chapter.

–  Slacken retaining frame bolts in the sequence -22 ... 1-.   Note Illustration shows retaining frame of left-side cylinder head. –  Carefully remove retaining frame. –  Mark and remove camshafts.   Note

To enable the locating pins -T40116- to be attached during installation on engines fitted with dowel pins -arrows- for retaining frame , drive out dowel pins using a suitable drift.

Installing   Note Renew gaskets and seals. l  Crankshaft -1- locked in position with locking pin -T40069-.   WARNING Wear safety goggles. –  Remove remaining sealant from cylinder head and retaining frame using rotating plastic brush or similar.   Caution Make sure that no sealant residue gets into the cylinder head or the bearings. –  Clean sealing surfaces; they must be free of oil and grease. –  Lubricate running surfaces of camshafts. –  Lay retaining frame aside onto workbench, on a soft surface.

–  Insert camshafts into retaining frame. l  Camshafts must be in correct position in axial bearings -arrows- in retaining frame. l  The ends of the piston rings -1- and -2- must point up or down, never to the side. –  Turn retaining frame upside down with camshafts inserted, keeping hold of the camshafts in the retaining frame.

–  Turn the camshafts until the threaded holes -arrows- point upwards. –  Check that camshafts are still in correct position in axial bearings in retaining frame.

–  Fit camshaft clamp -T40070- as shown in illustration and tighten bolts -arrows- to 20 Nm.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 1 mm). –  Turn retaining frame back up.

Vehicles up to approx. 08.2004: –  Apply the beads of sealant -1 ... 6- onto the clean sealing surfaces of the retaining frame as illustrated. l  The grooves on the sealing surface must be completely filled with sealant. l  The beads of sealant must project 1.5 … 2.0 mm above the sealing surface.   Note The beads of sealant must be applied exactly according to these instructions, otherwise excess sealant can get into the camshaft bearings.

Vehicles from approx. 08.2004: –  Apply a small amount of sealant in groove for gasket -3- in area of opening for camshaft control solenoid valve -arrows-. –  Press gasket into retaining frame and wipe off excess sealant from gasket and retaining frame. –  Apply the beads of sealant -1-, -2- and -4- onto the clean sealing surfaces of the retaining frame as illustrated. l  Width of sealant bead: 1.0 mm.   Note The beads of sealant must be applied exactly according to these instructions, otherwise excess sealant can get into the camshaft bearings.

All vehicles:   Note Fit and secure the retaining frame without delay, as the sealant starts hardening immediately. –  Fit retaining frame onto cylinder head. –  Insert locating pins -T40116- in retaining frame and cylinder head.

–  Fit retaining frame onto cylinder head without delay. –  Tighten retaining frame bolts evenly in the sequence -1 ... 22-, initially only hand-tight. l  The retaining frame should make contact with the cylinder head over the full surface. –  Tighten retaining frame bolts to final torque in the sequence -1 ... 22-.   Note t  Illustration shows retaining frame of left-side cylinder head. t  After installing the retaining frame, wait about 30 minutes for the sealant to dry.

–  Clean bore for sealing plug in cylinder head; it must be free of oil and grease. –  Coat outer circumference of sealing plug -arrow- with sealant; for sealant refer to → Electronic parts catalogue. –  Drive in sealing plug until flush.

–  Use impact extractor attachment -T10133/3- to pull out locating pins -T40116-. Perform further installation in reverse order, paying attention to the following:   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. –  Install exhauster pump for brake servo → Chapter. –  Install camshaft timing chains → Chapter. –  Install timing chain covers (left and right) → Chapter. –  Install cylinder head cover: left-side → Chapter, right-side → Chapter. Tightening torque

Component	Nm
Retaining frame to cylinder head	8 + 90° 1)2)
l  1) Renew bolts. l  2) 90° = one quarter turn.