Camshafts, removing and installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Fig 1: Identifying Puller T40001

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Puller T40001

Fig 2: Identifying Retainer 3036

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Retainer 3036

Removing

NOTE:

Sealing surfaces on guide frame at bottom and on cylinder head at top must not be worked.
Camshaft bearings are integrated in cylinder head or in guide frame. Before removing guide frame, tension on toothed belt must be released.
If guide frame was loosened, camshaft sealing ring and sealing cap must be replaced.

Remove cylinder head cover → Cylinder head cover, removing and installing
Remove camshaft adjuster → Camshaft adjuster, removing and installing
Remove toothed belt → Toothed belt, removing and installing

Fig 3: Counterholding Camshaft Gear Using 3036 Retainer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen camshaft gear with Retainer 3036.

Fig 4: Pulling Off Camshaft Gear Using Puller T40001, Claw T40001/6 And Claw T40001/7

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off camshaft gear using puller T40001 , claw T40001/6 and claw T40001/7.
Remove toothed belt guard at rear of cylinder head.
Loosen bolts of guide frame evenly from outside toward inside and remove guide frame.
Carefully remove camshaft upward and place on a clean surface.

Fig 5: Identifying Sealant Bead (D 154,103 A1) In Clean Groove Of Guide Frame

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove old sealant from guide frame groove and from sealing surfaces.
Prevent dirt and adhesive residue from entering cylinder head.

Installing

NOTE:

Sealing surfaces must be completely free of oil and grease.
The pistons must not be positioned at TDC.
Make sure that all roller cam followers make contact correctly on valve stem ends.

Oil journal surfaces of camshafts.

Fig 6: Bringing Marking On Camshaft Gear To Alignment With Marking On Toothed Belt Guard

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully insert camshafts into camshaft bearings of cylinder head. The cam lobes - A - of cylinder 4 must face toward one another.

Fig 7: Identifying Sealant Bead (D 154,103 A1) In Clean Groove Of Guide Frame

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply an even, light sealant bead into clean groove of guide frame.

NOTE:

Sealant must not be applied too thickly.
Attaching and bolting the guide frame should be performed without interruption because the sealant begins to harden immediately as soon as it contacts the sealing surfaces.
Note the expiration date of the sealing compound.

Fig 8: Setting Guide Frame In Place So That It Can Get By EGR Vacuum Regulator Solenoid Valve N18

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Set guide frame in place so that it can get by EGR Vacuum Regulator Solenoid Valve N18 - arrow -.
Replace guide frame bolts.
Gently tighten bolts from inside working toward outside in several stages.

Fig 9: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Finally, tighten bolts in sequence shown.
Drive in sealing cap with thrust piece 3334 approx. 1 to 2 mm deep.
Install camshaft seal → Sealing ring for exhaust camshaft, replacing
Install rear toothed belt cover.

Insert fitting key into camshaft.

Fig 10: Counterholding Camshaft Gear Using 3036 Retainer

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install camshaft gear. To tighten bolt, hold camshaft gear in place using Retainer 3036.

NOTE:

When turning camshaft, pistons may not be at TDC for any cylinder. Valves/pistons may be damaged.
Be sure fitting keys are properly seated.

Install toothed belt → Toothed belt, removing and installing
Install camshaft adjuster → Camshaft adjuster, removing and installing
Install cylinder head cover → Cylinder head cover, removing and installing
Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 11: Identifying Lock Carrier With Attachments

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

The rest of assembly is basically a reverse of disassembling sequence.

Torque specifications

Cylinder head, camshafts → Cylinder head, camshafts, overview