Camshafts and camshaft adjusters (left 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

Engine installed.

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

Fig 3: Removing Bolts And Toothed Belt Guard At Rear

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Loosen nuts - 1 -.
Remove bolts - 2 - and remove toothed belt guard at rear.

Fig 4: Disconnecting Electrical Harness Connector From Camshaft Adjustment Valve 2 N208

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - arrow - from Camshaft Adjustment Valve 2 N208.
Remove left cylinder head cover → Left cylinder head cover, removing and installing .

Fig 5: Disconnecting Electrical Harness Connector At Camshaft Position (CMP) Sensor 2 G163

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Disconnect electrical harness connector - arrow - at Camshaft Position (CMP) Sensor 2 G163.
Remove housing for Hall sensor.
Remove washer and cover for Hall sensor.
Rotate crankshaft at mounting bolt for toothed belt sprocket counterclockwise approx. 45° so that no pistons stand at TDC.

Fig 6: Identifying Camshaft TDC

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Verify camshaft TDC position again:

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

When reusing the 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 7: Identifying Distance Between Both Arrows Or Colored Markings Consists Of 15 Rollers Of Drive Chain

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The distance between both arrows or colored markings consists of 15 rollers of the drive chain.

NOTE:

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

Continued:

Fig 8: 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 chain tensioner retainer is fastened too tightly, the camshaft adjuster can be damaged.

Fig 9: Installing Camshafts Without Chain Into Cylinder Head And Tightening Bearing Caps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Independent of the existing markings on the 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 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 10: 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 11: Aligning Color Markings

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Align color markings - arrows -.

When using a new drive chain:

Fig 12: Distance Between Notches At Camshafts Must Be Distance Of 15 Rollers At Drive Chain

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Distance between notches - A - and - B - at camshafts must be distance of 15 rollers at drive chain. Illustration shows where first and fifteenth drive chain rollers must be installed on chain gears.

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 13: 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 14: Verifying Camshaft TDC

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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 15: 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 camshafts 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 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⁾
Toothed belt guard	Cylinder head	10 ³⁾
at rear on	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