Audi Workshop Service and Repair Manuals

Removing and installing camshafts - cylinder head (right-side)

Special tools and workshop equipment required

t	Puller -T10320-

t	Camshaft fitting tool -T40094-

t	Camshaft fitting tool -T40095-

t	Camshaft fitting tool -T40096-

t  Removal lever -80 - 200-

t  Counterhold tool -3036- t  Electric drill with plastic brush t  Safety goggles t  Sealant → Electronic parts catalogue Removing –  Remove timing chain (right-side) from camshaft: engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB → Chapter, engine code CAPA → Chapter.

–  Remove cylinder head cover (right-side) → Chapter.   Note Lay a cloth under the connection to catch escaping fuel.   Caution Protect fuel system against contamination. Rules for cleanliness when working on the injection system → Chapter. –  Disconnect fuel supply hose -1- and fuel return hose -2-.

–  Unscrew union nuts -1- and -2-. –  Remove bolts -arrows- and move fuel rail to one side (fuel hoses remain connected).

–  Use removal lever -80 - 200- to move electrical wiring harness clear -arrow-.   Note Disregard -items 1, 2-.

–  Slacken retaining frame bolts and nuts in the sequence -17 ... 1-.   Note Make sure you do not damage roller rocker fingers and compensation elements when removing camshafts. –  Carefully detach retaining frame and camshafts. Installing l  Tightening torques → Chapter „Cylinder head - exploded view“   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. Protect lubrication system against contamination. Cover exposed parts of the cylinder head.   WARNING Protect eyes against injuries. Wear safety goggles. –  Remove remaining sealant from cylinder head and retaining frame using rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease. –  Oil running surfaces of both camshafts.

Set up camshaft fitting tool -T40094- as follows: –  Insert support -T40094/2- in position -B-. –  Insert support -T40094/1- in position -C-.

–  Place exhaust camshaft -1- in supports -T40094/1- and -T40094/2-. –  Turn exhaust camshaft in such a way that it can be locked in „TDC“ position using locking device -arrow-.

–  Place inlet camshaft -2- in camshaft fitting tool -T40094-. l  The locating bar -3- must engage in the groove on the inlet camshaft. –  Place camshaft fitting tool -T40096- on teeth of inlet camshaft in such a way that the two arms of the tool engage on the two halves of the gear (one in each half, as shown in illustration). –  Tighten the clamping tool using the knurled wheel so that the faces of the gear teeth are in alignment. –  Slide exhaust camshaft -1- towards inlet camshaft -arrows- until gear teeth engage.

–  Check that camshafts are in correct position: l  Recesses -arrows- on both camshafts must point outwards.

–  Fit retaining frame -1- on both camshafts. l  All camshaft bearings must be seated on the camshafts. –  Attach camshaft fitting tool -T40095- to camshafts (align arms of bracket as required and tighten knurled nuts -2-). –  Apply tension to camshafts by tightening the knurled nuts -3- upwards.

–  Check if dowel pins -arrows- are fitted in cylinder head. Install missing dowel pins.   Note

Note the use-by date of the sealant. –  Cut off nozzle of tube at front marking (nozzle Ø approx. 1.5 mm).   Note

For illustration purposes, the retaining frame is shown without the camshafts. –  Turn retaining frame upside down.   Caution Make sure lubrication system is not clogged by excess sealant. The sealant beads must not be thicker than specified. –  Apply beads of sealant -arrows- onto clean sealing surfaces of retaining frame as shown in illustration. 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 retaining frame must be installed within 5 minutes after applying the sealant.   Caution Risk of damage to engine. Ensure that all roller rocker fingers contact the valve ends and compensation elements correctly.

–  Fit retaining frame together with both camshafts and camshaft fitting tool -T40095- onto cylinder head. –  Tighten bolts for retaining frame → Fig.. –  Remove camshaft fitting tool -T40095- and -T40096-.   Note After installing the retaining frame, wait about 30 minutes for the sealant to dry. Remaining installation steps are carried out in reverse sequence; note the following: –  Install cylinder head cover (right-side) → Chapter. –  Use suitable drift to drive in new sealing cap until flush. –  Install camshaft timing chain: engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB → Anchor, engine code CAPA → Anchor.   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 engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.