Camshafts, Removing and Installing

WARNING: This page is about a different car, the 2009 Audi S8, 2008 Audi S8, and 2007 Audi S8. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Locking Pin 3242

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Locking pin 3242

Fig 2: Camshaft Clamp T40070

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Camshaft Clamp T40070 , qty. 2

Fig 3: Impact Puller T10133/3 From The Tool Set T10133

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Impact puller T10133/3 from tool set T10133

Fig 4: Securing Pins

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Securing pins 1 set = qty. 2 T40116
Hand drill with plastic brush attachment
Protective glasses
Sealant

NOTE:

Here, removal and installation at left cylinder head is depicted in the following description.

Fig 5: Cylinder Head Ground Line & Electrical Connectors

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Removing

Remove engine → Engine, Removing .
Leave engine with transmission installed on scissor lift platform VAS 6131 A.
Remove camshaft timing chains from camshafts → Camshaft Timing Chain, Removing from Camshaft .
Remove Ground (GND) wire - 1 - from guide frame.

Disconnect electrical connectors - 2 - and - 3 -.
Remove high-pressure pump → 24 - MULTIPORT FUEL INJECTION (MFI) .

Fig 6: Guide Frame Bolts Tightening/Loosening Sequence

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Loosen guide frame bolts in sequence - 28 to 1 -.

NOTE:

Proceed in the same way with right guide frame.

Carefully remove guide frame and lay it on a soft surface on the workbench.

Fig 7: Removing/Installing Camshaft Locators T40070 On Both Cylinder Heads

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Remove Camshaft Clamp T40070 at left cylinder head.

Fig 8: Identifying Guide Frame Alignment Pins

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Mark camshafts and remove.

CAUTION: On engines equipped with guide frame alignment pins - arrows - , these must be driven out with a cotter pin driver.

Installing

NOTE:

Always replace gaskets and seals.

Fig 9: Installing/Removing Crankshaft Holder 3242 In Bore

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Secure crankshaft - 1 - using crankshaft holder 3242.

CAUTION: Wear safety glasses.

CAUTION: Make sure that no sealant residue enters the cylinder head and bearings.

Remove sealant residue on cylinder head and guide frame, e.g. with rotating plastic brush.
Clean sealing surfaces, they must be free of oil and grease.
Oil journal surfaces of camshafts.

Fig 10: Identifying Axial Bearings

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Set camshafts into guide frame.

The placement of the camshafts must be exactly within the axial bearings - arrows - of the guide frame.

Rotate guide frame with camshafts installed while holding camshafts inside the frame.

Fig 11: Identifying Threaded Holes In Camshafts Must Face Upward

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Rotate camshafts until threaded holes - arrows - point upward.
Check whether camshafts still lie exactly in axial bearings of guide frame.

Fig 12: Removing/Installing Camshaft Locators T40070 On Both Cylinder Heads

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Install camshaft clamp T40070 at intake and exhaust camshafts as shown in the illustration and tighten the bolts to 25 Nm.

Fig 13: Cutting Tube Nozzle At Front Marking

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Cut off nozzle on tube of sealant at front mark (diameter of nozzle approximately 2 mm).

Fig 14: Identifying Guide Seal & Sealant Beads

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Turn around guide frame again.
Lay a new seal - 2 - in guide frame groove.

NOTE:

Sealant beads must not be thicker than specified, otherwise extra sealant can enter camshaft bearing.

Apply sealant beads - 1, 3, 4 - on clean guide frame sealing surfaces as shown in illustration.

Thickness of sealant beads: 2.5 mm.

NOTE:

Because the sealant begins hardening immediately, guide frame must be promptly positioned and tightened.

Place guide frame on cylinder head.

Fig 15: Inserting Locating Pins T40116 In Guide Frame And Cylinder Head

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Insert locating pins T40116 in guide frame and cylinder head.

NOTE:

After installing guide frame, sealant must dry for approximately 30 minutes.

Fig 16: Guide Frame Bolts Tightening/Loosening Sequence

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Tighten guide frame bolts evenly by hand in sequence - 1 to 28 -.
Fasten guide frame bolts in sequence - 28 to 1 - until they stop.
Clean sealing plug hole in cylinder head. It must be free of oil and grease.

Fig 17: Driving Sealing Plugs In Flush

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Coat outer circumference of sealing plugs - arrows - with sealant .
Install sealing plugs so they are flush.

Fig 18: Removing Locating Pins T40116 Using Impact Puller T10133/3

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Remove locating pins T40116 with impact puller T10133/3.

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

Install high pressure pump → 24 - MULTIPORT FUEL INJECTION (MFI) .
Position camshaft timing chains on camshafts → Installing under Camshaft Timing Chain, Removing from Camshaft .
Install left and right timing chain covers → Installing under Left and Right Timing Chain Covers, Removing and Installing .
Install cylinder head cover: Left → Left Cylinder Head Cover, Removing and Installing , right → Right Cylinder Head Cover, Removing and Installing .

Install engine → Engine, Installing .

NOTE:

After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on 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.

Tightening specifications

Component	Nm
Bearing bracket to cylinder head	8 plus 90° 1)2)
1) Replace bolts. 2) 90° corresponds to a quarter turn.