Camshafts, Removing And Installing: Installing

WARNING: This page is about a different variant/trim than selected.

Fig 1: Crankshaft Locking Pin T40069

Courtesy of AUDI OF AMERICA, LLC

Tightening specifications. Refer to OVERVIEW - VALVETRAIN .

NOTE:

Replace the seals and sealing plugs.

Secure crankshaft -1- in "TDC" position using Crankshaft Locking PinT40069.
The hydraulic adjusting elements and roller rocker lever are inserted.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of engine.

WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Remove the sealant residue on the cylinder head and guide frame and the upper section of the oil pan, for example using a rotating plastic brush.

-- Clean the sealing surfaces; they must be free of oil and grease.

-- Check the screen -arrow- for dirt; clean it if necessary.

Fig 2: Identifying Screen

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The screen -arrow- is installed according to the version.

-- Oil running surfaces of both camshafts.

-- Insert the camshafts in the guide frame.

Fig 3: Compression Ring Ends -1, 2 And 3-

Courtesy of AUDI OF AMERICA, LLC

The placement of the camshafts must be exactly within the axial bearings -arrows- of the guide frame.
The compression ring ends -1, 2 and 3- must face up or down. They must never face sideways.

-- Rotate the guide frame with the camshafts inserted while holding them securely in the frame.

-- Rotate the camshafts until the threaded holes -arrows- face upward.

Fig 4: Camshafts

Courtesy of AUDI OF AMERICA, LLC

-- Check if the camshafts still lie in the guide frame axial bearings.

-- Install the Camshaft ClampT40133 in both cylinder heads and tighten -arrows- to 25 Nm.

Fig 5: Camshaft Adjuster T40133

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Note the expiration date of the sealing compound.

-- Cut the tube nozzle at the front marking (nozzle diameter: about 2 mm).

Fig 6: Cut Tube Nozzle At Front Marking

Courtesy of AUDI OF AMERICA, LLC

-- Rotate the guide frame again.

Fig 7: Applying Sealant Beads -4 Through 8- To Clean Sealing Surfaces On Guide Frame

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of contaminating camshaft bearing with excess sealant.

Do not apply sealant beads thicker than indicated.

-- Apply sealant beads -4 through 8- to the clean sealing surfaces on the guide frame as shown in the illustration.

Sealant bead thickness: 2.0 mm

-- Apply sealant beads -1 through 3- to the clean sealing surfaces on the guide frame as shown in the illustration.

Sealant bead thickness: 2.5 mm

NOTE:

The guide frame must be installed within 5 minutes after applying the sealant.

-- Place the guide frame on the cylinder head.

Fig 8: Aligning Guide Frame And Cylinder Head Using Locating Pins T40116

Courtesy of AUDI OF AMERICA, LLC

-- Install the Locating PinsT40116 into the guide frame and cylinder head.

-- Tighten the camshaft guide frame bolts. Refer to Figure.

Fig 9: Guide Frame Bolt Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

NOTE:

After installing the guide frame, let the sealant harden for approximately 30 minutes.

-- Clean the hole in the cylinder head of any oil and grease.

Fig 10: Identifying Sealing Plug

Courtesy of AUDI OF AMERICA, LLC

-- Coat the outer circumference of the sealing plug -arrow- with sealant; for the correct sealant.

-- Drive in the sealing plugs until they are flush.

-- Remove the Locating PinsT40116 with the Impact PullerT10133/3.

Fig 11: Remove The T40116 Using T10133/3

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal. Note the following:

-- Install the camshaft adjustment valve -N205- Camshaft Adjustment Valve 1 -N205- / Camshaft Adjustment Valve 2 -N208-. Refer to OVERVIEW - CYLINDER HEAD .

-- Install the high pressure pump motor housing and the high pressure pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Install the vacuum pump. Refer to Electrical Brake Vacuum Pump V192 .

-- Position the camshaft timing chain on the camshafts. Refer to CAMSHAFT TIMING CHAIN, REMOVING AND INSTALLING .

CAUTION:

Risk of damaging valves and piston heads after working on valve train.

The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves.
To ensure valves do not strike pistons when starting, carefully rotate engine at least two full revolutions.