Audi Workshop Manuals

Removing and installing camshafts Special tools and workshop equipment required

t  Assembly tool -T10352/2-

t  Counterhold tool -T10355-

t  Locking pin -T40011-

t  Thrust piece -T10174-

t  Assembly pin -T40196-

t  Spacers -T40191- Removing   Note t  Sealing surfaces at bottom of cylinder head cover and top of cylinder head must not be machined. t  The camshaft bearings are integrated into the cylinder head and cylinder head cover. The timing chain must be slackened before removing the cylinder head cover. t  Fit cable ties in the original positions when installing. –  Perform service position → Rep. gr.50.

–  Remove engine cover panel -arrows-. –  Detach air duct at bottom together with air hose.

–  Disconnect hose -1- from air cleaner. –  Disconnect air intake hose -2-. –  Pull air cleaner housing upwards -arrows-. –  Plug openings in turbocharger with sealing plugs from engine bung set -VAS 6122-.

–  Unplug electrical connectors -arrows- at actuators for camshaft adjustment.

–  Detach electrical connector for Lambda probe -1- from retainer. –  Release electrical connectors at ignition coils and unplug from ignition coils simultaneously. –  Remove bolts for ignition coils and pull out ignition coils.

–  Remove actuators for camshaft adjustment -arrows-.

–  Disconnect crankcase breather hose -1-. –  Remove bolts -arrows-, detach crankcase breather system and disconnect from crankcase breather hose -2- in direction of -arrow-.

–  Disconnect pipe -arrows-. –  Unplug electrical connector -1- from Hall sender -G40-

–  Unplug connector -1- from exhaust camshaft control valve 1 -N318- and connector -2- from exhaust camshaft control valve 1 -N205-. –  Unscrew bolts -arrows- and remove camshaft control valve 1 -N205- and exhaust camshaft control valve 1 -N318-.

–  Unscrew bolts -1 to 6- and remove timing chain cover (top).

Caution The timing valves have a left-hand thread. –  Turn assembly tool -T10352/2- in direction of -arrow- to remove timing valve (left and right sides).

–  Remove bolts -arrows- and detach bearing saddle.

–  Turn vibration damper to „TDC“ position -arrow- using counterhold tool -T10355-. l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom). l  The markings -1- on the camshafts must face upwards.

Caution Risk of irreparable damage to engine. Only insert assembly pins -T40196- in points marked in illustration. –  Insert assembly pins -T40196- as shown in illustration. –  Turn crankshaft 2 rotations in direction of engine rotation.   Note Engine must be at „TDC“ position again. –  Remove assembly pins -T40196-.

–  Use a waterproof pen to mark camshaft timing chain and cylinder head -arrows- to markings on chain sprocket -1-.

–  Remove sealing plug -arrow-.   Note

Illustration shows slackening chain tensioner with timing chain cover removed. –  Compress circlip -arrow- for chain tensioner. –  Turn crankshaft to rotate engine anti-clockwise (in opposite direction of normal rotation) and secure chain tensioner using locking tool -T40267-.

Note Inlet camshaft will move in direction of engine rotation. –  Remove bolt -1- and detach tensioning rail -2- downwards. –  Use screwdriver to release catch and press off top guide rail -3- forwards. –  Remove camshaft timing chain from camshaft sprockets.   Caution Avoid damage to valves and piston crowns. Do not turn the crankshaft after the camshaft timing chain has been removed from the cylinder head. –  Remove high-pressure pump → Rep. gr.24. –  Remove vacuum pump → Rep. gr.47.

–  Remove cylinder head cover bolts in the sequence -1 ... 6-. –  Detach cylinder head cover. –  Detach camshafts.   Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine. Installing l  Tightening torques → Chapter „Valve gear - exploded view“   Note t  The sealing surfaces must be free of oil and grease. t  Pistons must not be at TDC. t  Ensure that all roller rocker fingers contact the valve ends correctly. –  Remove sealant remaining on cylinder head with flat scraper.   WARNING Protect eyes against injuries. Wear safety goggles.   Caution Protect lubrication system and bearings against contamination. Cover exposed parts of the engine.

–  Remove sealant residue in groove of cylinder head cover and on sealing surfaces, e.g. using a rotating plastic brush. –  Clean sealing surfaces; they must be free of oil and grease. –  Oil running surfaces of both camshafts.

WARNING Protect eyes against injuries. Wear safety goggles. –  Lock camshaft with spacers -T40191- as shown in illustration; if necessary, move sliders to correct positions.   Note If available, use second set of spacers -T40191-, or re-position -T40191/1-.

–  Place camshafts in cylinder head; markings -arrows- must be positioned as shown in illustration.

–  Check alignment -arrows- of camshafts.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 2 mm).

–  Apply silicone sealant onto clean sealing surface of cylinder head cover, as illustrated -arrows-. t  Thickness of sealant bead: 2 ... 3 mm.   Note t  The cylinder head cover must be installed within 5 minutes after applying the silicone sealant. t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe. t  Note the use-by date of the sealant. Sealant → Electronic parts catalogue –  Fit cylinder head cover on cylinder head. –  Renew bolts for cylinder head cover. –  Tighten bolts in several stages; tightening sequence → Fig..   Note Take care to keep cylinder head cover straight.

–  Turn vibration damper to „TDC“ position -arrow- using counterhold tool -T10355-. l  Notch on vibration damper must align with arrow marking on cover for timing chains (bottom).   Note The camshaft timing chain links with markings must be positioned at the markings on the chain sprockets and on the cylinder head. –  Position camshaft timing chain links with coloured markings at markings on camshaft chain sprockets; to do so, turn camshafts using assembly tool -T40266-. –  Check valve timing → Chapter.

–  Attach bearing saddle and screw in bolts -arrows- hand-tight. –  Remove locking tool -T40267-. –  Tighten bolts -arrows- for bearing saddle → Chapter. –  Install timing valve → Item.

–  Insert assembly pins -T40196- as shown in illustration. –  Turn crankshaft 4 rotations in direction of engine rotation. –  Remove assembly pins -T40196-. –  Install timing chain cover (top) → Chapter. –  Install vacuum pump → Rep. gr.47. –  Install high-pressure pump → Rep. gr.24. –  Reset service position → Rep. gr.50. –  Install air cleaner housing → Rep. gr.24. Further assembly is basically carried out in reverse order of dismantling.