Audi Workshop Service and Repair Manuals

Removing and installing camshafts

t  Special wrench -T10035-

t  Tool set for FSI engines -T10133-

t  Locating pins -T40116- t  Adapter -T40257- t  Wrench -T40263- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue Removing   Note The following description is for removing and installing on cylinder head (left-side). –  Remove timing chain from camshafts on relevant side → Chapter.

–  Unplug electrical connectors: 1 -  at camshaft control valve 2 -N208- 2 -  at fuel pressure sender -G247- 3 -  at high-pressure pump (left-side) 4 -  at Hall sender 2 -G163- –  Remove bolt -5- and move wiring harness clear.

–  Remove high-pressure pump → Rep. gr.24.

–  Remove locking pin -3242-.

–  Fit adapter -T40257- onto wrench -T40263-. –  Position adapter on bolts of vibration damper. l  Notch -arrow A- on adapter -T40257- must point to coloured line -arrow B- on vibration damper.   Note Semi-circular recess on adapter -T40257- can be disregarded.   Caution Avoid damage to valves and piston crowns. When performing the following steps, the crankshaft must not be at „TDC“ position at any cylinder. –  Using counterhold tool -T10172- with -T10172/7-, turn crankshaft back through 40° out of „TDC“ position in opposite direction to normal rotation -arrow-.

–  Remove camshaft clamp -T40070--arrows-.

–  Loosen and remove bolts for retaining frame 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 detach. –  Mark fitting location of camshafts for re-installation and remove. Installing l  Tightening torque → Fig. „„Retaining frame for camshafts - tightening torque and sequence““   Note t  Renew seals and gaskets. t  Renew the bolts tightened with specified tightening angle.   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 sealing surfaces; they must be free of oil and grease. –  Oil running surfaces of both 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 the end of the shaft must be positioned as shown in the illustration.

Cylinder head (right-side): 1 -  Exhaust camshaft 2 -  Inlet camshaft l  The groove on the end of the shaft must be positioned as shown in the 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 nozzle of tube at front marking (nozzle Ø approx. 2 mm).

–  Fit gasket -2- in grooves on retaining frame.   Caution Make sure excess sealant does not contaminate camshaft bearings. The beads of sealant must not be thicker than specified. –  Apply beads of sealant -1, 3, 4- onto clean sealing surfaces of retaining frame as shown in illustration. l  Width of sealant beads: 2.5 mm.   Note The retaining frame must be installed within 5 minutes after applying the sealant. –  Fit retaining frame onto cylinder head.   Note Make sure that camshafts can be inserted into axial bearing of retaining frame without applying force.

–  Insert locating pins -T40116- in retaining frame and cylinder head.

–  Tighten bolts for retaining frame → Fig..   Note After installing the retaining frame, the sealant must dry for approx. 30 minutes.

–  Drive in sealing plugs -arrows- until flush.

–  Use impact extractor attachment -T40116- to pull out locating pins -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 Use pliers to counterhold socket when tightening 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. –  Secure camshaft clamp -T40070- to exhaust camshaft only hand-tight, to avoid damaging the thread (assistance of second mechanic required).

–  Tighten bolts on camshaft clamp -T40070- to 25 Nm -arrows-.

–  Rotate crankshaft in normal direction of rotation -arrow- to „TDC“.

–  Screw locking pin -3242- into hole (20 Nm); if necessary, turn crankshaft -1- backwards and forwards slightly to fully centralise locking pin. Remaining installation steps are carried out in reverse sequence; note the following: –  Install high-pressure pump → Rep. gr.24. –  Fit timing chains on camshafts → 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.