Camshafts and camshaft adjusters, removing and installing: Installing

Replace rubber/metal gasket for camshaft adjuster and apply a thin coat of sealant D 454 300 A2 to shaded area.

Fig 1: Locating Shaded Area For Sealant D 454 300 A2
Courtesy of AUDI OF AMERICA, INC.
Install drive chain on camshaft sprockets as follows:
- When old chain is being used again, install chain so that paint markings (arrow) are in line.
  
  Fig 2: Identifying Paint Markings On Old Camshaft Chain
  Courtesy of AUDI OF AMERICA, INC.
- When a new chain is being installed, distance between notches -A- and -B- on camshafts must be 16 rollers on chain. Illustration shows exact positions of 1st and 16th rollers on sprockets. See Fig 3.
- Notch -A- is offset slightly towards inside in relation to chain roller -1-.
Insert camshaft adjuster inside chain (second mechanic required).

Fig 3: Installing New Camshaft Chain
Courtesy of AUDI OF AMERICA, INC.
Locate camshafts with chain and camshaft adjuster in cylinder head.
Oil camshaft bearing surfaces.

NOTE:

The dowel sleeves for the bearing caps and camshaft adjuster must be in the cylinder head.
Install the bearing caps so that the markings on the bearing caps can be read from the inlet side of the cylinder head.

Tighten bolts securing chain tensioner (watch position of dowel sleeves).
Tighten bearing caps 2 and 4 of inlet and exhaust camshafts alternately and in diagonal sequence (watch position of dowel sleeves). See Fig 4.
Install two bearing caps next to chain sprockets on inlet and exhaust camshafts.

Fig 4: Locating Camshaft Bearing Caps
Courtesy of AUDI OF AMERICA, INC.
Check correct setting of camshafts:
- Two markings on camshafts must be in line with two arrows on bearing caps -arrows-.
  
  Fig 5: Identifying Markings On Camshafts
  Courtesy of AUDI OF AMERICA, INC.
- Distance between two arrows on bearing caps (or between paint markings) is 16 rollers on chain. See Fig 6.
- Notch on exhaust camshaft is offset slightly towards inside in relation to chain roller -1-.
Fig 6: Identifying Distance Between Camshaft Bearing Caps Or Chain Rollers
Courtesy of AUDI OF AMERICA, INC.
Prepare shaded areas on double bearing cap -1- and bearing cap -7-.

Fig 7: Identifying Double Bearing Caps
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... by applying a thin coat of sealant D 454 300 A2 and install bearing caps (watch position of dowel sleeves).

Fig 8: Identifying Areas On Double Camshaft Bearing Caps To Apply Sealant D 454 300 A2
Courtesy of AUDI OF AMERICA, INC.
Install remaining bearing caps (watch position of dowel sleeves).
Install new oil feed lines for camshaft bearings.
Install new oil seals for inlet and exhaust camshafts;
Installing, see OIL SEALS IN CYLINDER HEADS, REPLACING
Remove retainer for chain tensioner 3366.

NOTE:

When new lifters have been installed the engine must not be started for about 30 minutes. The hydraulic compensation elements must settle (otherwise valves will strike pistons). Then turn crankshaft two full revolutions before starting.
After working on the valve gear, turn over the engine carefully at least two revolutions by hand to ensure that none of the valves make contact when the starter is operated.

Seal end points of joints between bearing caps and cylinder head.
Before installing cylinder head cover and gasket, carefully apply a small quantity of sealant D 454 300 A2 at the four end points of sealing surfaces on cylinder head -arrows-, using a small screwdriver.

Fig 9: Locating Seal End Points Of Joints Between Bearing Caps And Cylinder Head
Courtesy of AUDI OF AMERICA, INC.
Install cylinder head covers. See CYLINDER HEAD COVERS, REMOVING AND INSTALLING .
Install toothed belt. See TOOTHED BELT, REMOVING AND INSTALLING .
Install ribbed belt. See RIBBED BELT, REMOVING AND INSTALLING .