Camshafts and camshaft adjusters (right cylinder head), removing and installing

WARNING: This page is about a different car, the 2006 Audi A8, 2005 Audi A8, and 2004 Audi A8. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Installation of camshaft drive chain to left and right cylinder heads differ basically. Note different procedures!

Special tools, testers and auxiliary items required

Fig 1: Bracket For Chain Adjustment 3366

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bracket For Chain Adjustment 3366

Fig 2: 3202/1 Pull Sleeve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Seal installer 3202

Sealant

Removing

Remove engine → Engine, removing and installing .
Toothed belt, removing → Toothed belt, removing and installing .
Remove camshaft gear.

Fig 3: Removing Idler Pulley & Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove idler pulley - arrow -.
Remove bolts - 1 - and - 2 - and remove toothed belt guard at rear.

Fig 4: Disconnecting Electrical Harness Connector At Camshaft Position (CMP) Sensor G40

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - at Camshaft Position (CMP) Sensor G40.
Remove housing for Hall sensor.
Remove washer and cover for Hall sensor.
Disconnect electrical harness connector at camshaft adjustment solenoid valve.

Remove right cylinder head cover → Right cylinder head cover, removing and installing .
Rotate crankshaft at mounting bolt for toothed belt sprocket counterclockwise approx. 45° so that no pistons stand at TDC.

Fig 5: Verifying Camshaft TDC

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Verify camshaft TDC position again:

The two camshaft markings must align with both arrows on bearing caps.

When reusing old drive chain:

Clean drive chain and camshaft chain sprockets across from both arrows on bearing caps and mark installed position with a color marking.

Fig 6: Identifying Distance Between Both Arrows Or Colored Markings Consists Of 16 Rollers Of Drive Chain

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The distance between both arrows or colored markings consists of 16 rollers of drive chain.
The notch on intake camshaft is slightly offset inward toward drive chain roller - 16 -.

NOTE:

Do not mark chain using a center punch or similar means!

Continued:

Fig 7: Securing Camshaft Adjuster Or Chain Tensioner Using Bracket For Chain Adjustment 3366

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure camshaft adjuster using Bracket For Chain Adjustment 3366.

NOTE:

If the chain tensioner retainer is fastened too tightly, the camshaft adjuster can be damaged.

Fig 8: Installing Camshafts Without Chain Into Cylinder Head And Tightening Bearing Caps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Independent of existing markings on bearing caps, mark sequence and installation position on all bearing caps, as shown in the illustration.
For marking, clean bearing cap and use waterproof felt pen.
Remove mounting bolts of camshaft adjuster - 10 -.
Remove bearing cap 1.

Remove bearing caps 2, 4, 6, 8 and 9 and lay on a clean surface in the corresponding sequence.
Alternating in diagonal sequence, loosen bearing caps 3, 5 and 7 of intake and exhaust camshafts and remove.
Raise both camshafts with camshaft adjuster.

Installing

Replace bolts for camshaft bearing and camshaft adjuster.
Replace half-round sealing plugs.
Remove sealant residue from cylinder head and bearing caps.

Fig 9: Replacing Rubber/Metal Camshaft Adjuster Gasket And Spreading Thin Layer Of Sealant On Hatched Surface

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Replace rubber/metal camshaft adjuster gasket and spread thin layer of sealant on hatched surface.

Sealant

Place drive chain onto camshaft chain sprockets as follows:

When using old drive chain:

Fig 10: Aligning Color Markings

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Align color markings - arrows -.

When using a new drive chain:

Fig 11: Identifying Distance Between Notches At Camshafts Must Be Distance Of 16 Rollers At Drive Chain

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Distance between notches - A - and - B - at camshafts must be distance of 16 rollers at drive chain. Illustration shows where first and sixteenth drive chain rollers must be installed on chain gears.
Notch - B - is slightly offset inward toward chain roller - 16 -

Continued:

Slide camshaft adjuster between drive chain (2nd technician needed).
Install camshafts with drive chain and camshaft adjuster in cylinder head.
Oil running surfaces of both camshafts.

NOTE:

Alignment bushings for bearing caps and camshaft adjuster must be installed in cylinder head.

Fig 12: Installing Camshafts Without Chain Into Cylinder Head And Tightening Bearing Caps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install bearing caps 3, 5, and 7 according to marking.
Tighten bearing caps 3, 5 and 7 of intake and exhaust camshafts in alternating diagonal sequence.
Tighten camshaft adjuster - 10 -.
Remove Bracket For Chain Adjustment 3366.

Check whether camshafts are correctly adjusted:

Fig 13: Verifying Camshaft TDC

Courtesy of VOLKSWAGEN UNITED STATES, INC.

The two camshaft markings must align with both arrows on bearing caps - arrows -.

NOTE:

So that both markings line up, turn camshaft slightly back or forth if necessary.

Fig 14: Coating Hatched Surface Of Double Bearing Cap As Well As Outer Bearing Cap Next To Camshaft Adjuster With Sealant

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Lightly coat hatched surface of double bearing cap as well as outer bearing cap next to camshaft adjuster with sealant and install bearing cap.

Sealant

Install remaining bearing caps.
Replacing and installing oil seals for intake and exhaust camshaft → Camshaft seals, replacing for camshaft or → Camshaft Position (CMP) Sensor seals, replacing for camshaft position sensor.
Carefully drive in cap using retractors 3202.
Rotate crankshaft at mounting bolt for toothed belt sprocket clockwise approx. 45° to TDC again and secure crankshaft using locking pin.

Further installation is in reverse order of removal, note the following:

Install toothed belt (adjust timing) → Toothed belt, removing and installing .
Install cylinder head cover → Right cylinder head cover, removing and installing .
Install engine → Installing .
Install torque support → Torque support (with torque support valve N382), assembly overview .

NOTE:

After installing the camshafts, the engine may not be started for approx. 30 minutes. The hydraulic equalization elements must seat themselves (otherwise the valves will crash into the pistons).
After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

Torque specifications

Component		Nm
Bearing cap to cylinder head		5 + 90° ¹⁾²⁾
Camshaft adjuster to cylinder head		5 + 90° ¹⁾²⁾
Rear toothed belt cover to	Cylinder head	10 ³⁾
	Coolant pump	10
Idler roller to cylinder head		22

¹⁾ Replace bolt
²⁾ 90° Corresponds to a quarter turn.
Insert ³⁾ using locking compound; locking compound