Audi Workshop Service and Repair Manuals

Removing and installing camshafts

Special tools and workshop equipment required

t	Special wrench -T10035-

t	Puller -T10133/3-

t	Adapter -T40058-

t	Locating pins for retaining frame -T40116-

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Electronic parts catalogue

Removing l  Engine removed and in position on scissor-type assembly platform -VAS 6131 A- with gearbox attached.   Note The following description is for removing and installing on cylinder head (left-side). –  Remove timing chains from camshafts: vehicles up to 03.2007 → Chapter, vehicles from 03.2007 onwards → Chapter. –  Unplug electrical connector at Hall sender for inlet camshaft -arrow-. –  Remove high-pressure pump → Rep. Gr.24.

–  Unscrew locking pin -3242- from sump (top section).

Caution To prevent the valves from striking the piston, rotate crankshaft and make sure that none of the pistons is in “TDC” position when performing the following work steps. –  Insert guide pin of adapter -T40058- as follows: l  The smaller-diameter section -arrow 1- faces the engine. l  The larger-diameter section -arrow 2- faces the adapter.

–  Using adapter -T40058- turn the crankshaft through 40° out of “TDC” position in opposite direction of normal rotation -arrow-.

–  Remove camshaft clamp -T40070- at left cylinder head.

–  Slacken retaining frame bolts in the sequence -24 ... 1-.   Note Perform the same procedure (laterally reversed) on retaining frame (right-side). –  Carefully release retaining frame from bonded joint and set it down on a soft surface on workbench. –  Mark position of camshafts and remove.

Caution On engines fitted with dowel pins -arrows- for retaining frames, use roll-pin drift to drive out dowel pins. Installing   Note Renew gaskets and seals.   WARNING Wear safety goggles. –  Remove sealant residue from cylinder head and retaining frame using a 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. –  Insert camshafts in cylinder head; note position of camshafts to make sure retaining frame is fitted free of stress.

Cylinder head (left-side): 1 -  Inlet camshaft 2 -  Exhaust camshaft l  The groove on shaft end must be positioned as shown in illustration.

Cylinder head (right-side): 1 -  Exhaust camshaft 2 -  Inlet camshaft l  The groove on shaft end must be positioned as shown in illustration.

Continuation for both sides: –  Check position of ends of rectangular section seals. l  The ends of the rectangular section seals -1- and -2- must point up or down, never to the side.   Note

Note the use-by date of the sealant. –  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø).

–  Fit new gasket -2- in grooves on retaining frame. –  Apply the beads of sealant -1, 3, 4- onto the clean sealing surfaces of the retaining frame as illustrated. l  Width of sealant beads: 2.5 mm.   Note The sealant beads must not be thicker than specified, otherwise excess sealant could enter the camshaft bearings. –  Immediately fit retaining frame onto cylinder head.

–  Fit locking pins for retaining frame -T40116- in retaining frame and cylinder head.   Note t  The retaining frame should be fitted and secured without delay, as the sealant starts hardening immediately. t  After installing the retaining frame, wait about 30 minutes for the sealant to dry.

–  Tighten retaining frame bolts in the sequence -1 ... 24- evenly, initially only hand-tight. –  Tighten retaining frame bolts to final torque in the sequence -1 ... 24-.

–  Knock in sealing plugs -arrows- until flush.

–  Pull out locking pins for retaining frame -T40116- using puller -T10133/3-.

–  Turn inlet camshaft to “TDC” position; to do so, fit a socket (24 mm) -item 1- between inlet camshaft and camshaft adjuster bolt -2- and secure camshaft adjuster bolt to camshaft as shown in illustration.   Note If necessary, use pliers to counterhold socket when tightening securing bolt. –  Apply lever or ratchet with special wrench -T10035- and turn camshaft until threaded hole for camshaft clamp -T40070- points upwards. –  Initially screw bolt for camshaft clamp -T40070- only a few turns into inlet camshaft. l  The camshaft clamp -T40070- is positioned correctly if the holes for the cylinder head bolts remain free.

–  Fit camshaft adjuster bolt -2- and socket (24 mm) -item 1- onto exhaust camshaft. –  Turn exhaust camshaft until threaded hole for camshaft clamp -T40070- points upwards. –  At the same time apply open-end spanner (24 mm) to camshaft clamp -T40070- and pivot camshaft clamp -T40070- towards exhaust camshaft -arrow- until camshaft clamp can be fastened. –  Fit camshaft clamp -T40070- to exhaust camshaft only hand-tight; make sure thread is not damaged (assistance of 2nd mechanic required).

–  Tighten bolts for camshaft clamp -T40070- to 25 Nm.

–  Using adapter -T40058- turn the crankshaft in the normal direction of rotation -arrow- to “TDC”.

–  Screw locking pin -3242- into bore (tightening torque: 20 Nm); if necessary, turn crankshaft backwards and forwards slightly to fully centralise locking pin. Remaining installation steps are carried out in reverse sequence; note the following:   Note t  Engine is not to be rotated for approx. 30 minutes after installing camshafts. 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. –  Position timing chains on camshafts → Anchor. –  Install timing chain covers (left and right) → Anchor. –  Install cylinder head cover: left-side → Chapter, right-side → Chapter. Tightening torque

Component	Nm
Retaining frame to cylinder head	8