Audi Workshop Service and Repair Manuals

Removing and renewing camshafts or camshaft bearings - cylinder bank 1 (right-side) Special tools and workshop equipment required

t  Counterhold tool -T10172- with adapter -T10172/5-

t  Adjustment pin -T40060-

t  Camshaft fitting tool -T40096-

Removing –  Remove timing chain from inlet camshaft → Chapter. l  Crankshaft -1- locked in „TDC“ position with locking pin -3242-.

–  Check „TDC“ position of camshafts: l  It should be possible to lock the inlet camshaft -1- with the adjustment pin -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. l  Exhaust camshaft -2- must be set so that groove -arrow B- is parallel above joint -arrow A- between bearing pedestal and bearing cap.

–  Place camshaft fitting tool -T40096- on teeth of inlet camshaft so that the two arms of the tool engage on the two halves of the gear (one in each half, as shown in illustration). 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.

–  Pull off adjustment pin -T40060-. –  Screw two bolts for camshaft chain sprocket five turns into threaded holes in camshaft, as shown in illustration.

–  Fit counterhold tool -T10172- with adapter -T10172/5- on both bolts and turn camshafts approx. 30° in anti-clockwise direction -arrow- until groove -arrow A- in camshaft points vertically to sealing surface -arrows B- of cylinder head.   Caution Risk of damage to valves. Do not turn camshafts any further than specified.

–  Loosen bearing cap bolts in the sequence -12 ... 1-.   Note Make sure you do not damage the roller rocker fingers and hydraulic compensation elements when removing the camshafts. –  Carefully detach bearing caps and camshafts.

Installing l  Tightening torques → Chapter „Valve gear - exploded view“ l  Crankshaft locked in „TDC“ position with locking pin -3242-. –  Place camshaft fitting tool -T40096- on teeth of inlet camshaft so that the two arms of the tool engage on the two halves of the gear (one in each half, as shown in illustration). 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.

To prevent installation at the wrong locations, the camshaft bearing pedestals and bearing caps for cylinder bank 1 are marked at the factory on the exhaust side:

Cylinder bank 1 (right-side)
R1/R1	Front
R2/R2	Front centre
R3/R3	Rear centre
R4/R4	Rear

–  Fit camshaft bearing pedestals „I, II and III“ on cylinder head. l  The oil drillings -arrow 1- in the cylinder head must be in line with the oil passages -arrow 2- in the bearing pedestals.

–  Fit camshaft bearing pedestal „IV“ on cylinder head. l  Both dowel sleeves -arrows- must be inserted in holes in bearing pedestal. l  Dowel sleeves must engage in holes in cylinder head.

–  Check that bearing pedestals are positioned correctly: l  The round side -arrow 2- faces the inlet side. l  The square side -arrow 1- faces the exhaust side.

–  Insert camshafts in bearing pedestals in „TDC“ position. l  It should be possible to lock the inlet camshaft -1- with the adjustment pin -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. l  Exhaust camshaft -2- must be set so that groove -arrow A- is parallel above joint -arrow B- between bearing pedestal and bearing cap. –  Fit matching bearing caps on bearing pedestals.

–  Wrap one cable tie -arrows- on each side around bearing pedestal and bearing cap and secure.   Note The cable ties help to keep the camshafts and camshaft bearings straight when they are tightened.

–  Pull off adjustment pin -T40060-. –  Screw two bolts for camshaft chain sprocket five turns into threaded holes in camshaft, as shown in illustration.

–  Fit counterhold tool -T10172- with adapter -T10172/5- on both bolts and turn camshafts approx. 30° in anti-clockwise direction -arrow- until groove -arrow A- in camshaft points vertically to sealing surface -arrows B- of cylinder head.   Caution Risk of damage to valves. Do not turn camshafts any further than specified.

–  Tighten bearing cap bolts → Fig..

–  Fit counterhold tool -T10172- with adapter -T10172/5- on both bolts and turn camshafts approx. 30° in clockwise direction -arrow- until groove -arrow A- in camshaft is aligned with hole -arrow B- for adjustment pin -T40060-.

–  Check „TDC“ position of camshafts: l  It should be possible to lock the inlet camshaft -1- with the adjustment pin -T40060-. l  The side pin -arrow- on the adjustment pin -T40060- must be in line with the imaginary line between the adjustment pin and the centre of the camshaft. l  Exhaust camshaft -2- must be set so that groove -arrow A- is parallel above joint -arrow B- between bearing pedestal and bearing cap. Remaining installation steps are carried out in reverse sequence; note the following: –  Remove camshaft fitting tool -T40096-. –  Install camshaft timing chains → 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 engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.