Audi Workshop Service and Repair Manuals

Removing and installing camshafts

t	Diesel injection pump locking pin -3359-

t	Counterhold tool -T10051-

t	Puller -T10052-

t	Camshaft fitting tool -T40094-

t	Camshaft fitting tool -T40095-

t	Clamping tool -T40096/1-

Removing

–  Remove engine cover panel -arrows-. –  Take out noise insulation at injectors. –  Remove injectors → Rep. gr.23. –  Remove fuel rail → Rep. gr.23. –  Detach toothed belt from camshaft and high-pressure pump → Chapter. –  Detach cylinder head cover → Chapter.

–  Unscrew bolts -1- on camshaft sprocket. –  Detach camshaft sprocket from hub.

–  Counterhold hub with counterhold tool -T10051- and loosen bolt -1- securing hub. –  Unscrew securing bolt of hub approx. 2 turns.

–  Set up puller -T10052- and align it with holes in hub. –  Tighten securing bolts -1-. –  Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.   Note Use 30 mm spanner to hold puller. –  Detach hub from taper of camshaft. –  Remove vacuum pump → Rep. gr.47.

–  Disconnect vacuum hose -1-.

–  Remove bolts -2- and -4-.   Note Coolant hoses -1- and -2- must not be detached. –  Remove bolts -arrows- and tie up exhaust gas recirculation cooler.

–  Unfasten bolts -arrows- and remove bracket for exhaust gas recirculation.

–  Remove bolts securing retaining frame in the sequence -24 ... 1-. –  Detach retaining frame. –  Mark fitting location of camshafts for re-installation and remove. Installing Tightening torques → Chapter „Valve gear - exploded view“   Note Use silicone sealant to seal sealing surface between retaining frame and cylinder head.   Caution Make sure axial bearings in retaining frame are not damaged. The camshafts MUST be installed using the camshaft fitting tool -T40094- as described in the following. –  Remove remaining sealant from cylinder head and retaining frame using rotating plastic brush or similar.   Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine.   WARNING Protect eyes against injuries. Wear safety goggles. –  Remove remaining sealant from cylinder head and retaining frame using rotating plastic brush or similar. –  Clean surfaces; they must be free of oil and grease.   Note –  Oil running surfaces of both camshafts.

Set up camshaft fitting tool -T40094- as follows: –  Secure supports -T40094/9- and -T40094/10- (with -T40094/11-) to base plate, as shown in illustration. If necessary, remove any supports already attached at these positions.

–  Fit support -T40094/1- onto position -F- and support -T40094/2- onto position -A-.

–  Place inlet camshaft in supports -T40094/1- and -T40094/2-. –  Turn inlet camshaft in such a way that it can be locked in „TDC“ position using locking device -arrow 1-. l  Recess -arrow 2- for cylinder head bolt must face outwards.

–  Place exhaust camshaft in supports -T40094/9- and -T40094/11-. –  Lock exhaust camshaft with top section -T40094/11-. l  The lug -1- on the top section must engage in the slot -2- in the camshaft, –  Place clamping tool -T40096/1- on teeth of exhaust camshaft so that the two arms of the tool engage in the two halves of the gear. l  The wider arm must engage in the wider half of the gear. –  Tighten the clamping tool using the knurled wheel so that the faces of the gear teeth are in alignment. –  Slide inlet camshaft towards exhaust camshaft until gear teeth -arrows- engage.

–  Fit retaining frame on camshafts. l  All camshaft bearings must be seated on the camshafts. –  Position camshaft fitting tool -T40095- and fix camshafts in position in retaining frame, as shown in illustration. –  Detach top section -T40094/11-.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 2 mm). –  Apply beads of sealant (approx. 2 ... 3 mm width) -arrows- onto clean sealing surfaces of cylinder head as illustrated.   Note

The sealant beads must not be thicker than specified, otherwise excess sealant could enter the camshaft bearings. –  Take camshafts together with retaining frame, camshaft fitting tool -T40095- and clamping tool -T40096/1- out of camshaft fitting tool -T40094- and insert components carefully into cylinder head.

–  Tighten retaining frame bolts in the sequence -1 ... 24- hand-tight initially. l  The retaining frame should make contact with the cylinder head over the full surface. –  Tighten retaining frame bolts in the sequence -1 ... 24- to final torque. Tightening torque: → Fig. –  Remove camshaft fitting tool -T40095- and clamping tool -T40096/1-. Perform further installation in reverse order, paying attention to the following: –  Renew camshaft oil seal → Chapter. –  Use suitable drift to drive in new sealing cap → Item at cylinder head until flush. –  Install vacuum pump → Rep. gr.47. –  Install cylinder head cover → Chapter.   Caution Avoid damage to valves and piston crowns after working on valve gear. t  The hydraulic tappets have to settle; wait for approx. 30 minutes after installing camshafts before starting engine. t  Turn the crankshaft carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.