Camshaft, Removing And Installing: Installing

Fig 1: Identifying Crankshaft Holder T40069 In Hole, Removal/Installation

Courtesy of AUDI OF AMERICA, LLC

• Secure crankshaft -1- in "TDC" position using Crankshaft Locking Pin T40069.
• The hydraulic adjusting elements and roller rocker lever are inserted.

Fig 2: Cleaning Sealing Surfaces

Courtesy of AUDI OF AMERICA, LLC

-- Remove any sealant residue on the cylinder head and the guide frame -1- using a rotating plastic brush.

-- Clean any oil or grease off the sealing surfaces.

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

Fig 3: Identifying Screen

Courtesy of AUDI OF AMERICA, LLC

-- Oil running surfaces of both camshafts.

-- Insert the camshafts in the guide frame.

Fig 4: Identifying 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 5: Identifying Camshaft Threaded Holes

Courtesy of AUDI OF AMERICA, LLC

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

-- Install the Camshaft Clamp T40133 in both cylinder heads and tighten -arrows- to 25 Nm.

Fig 6: Identifying Camshaft Adjuster T40133

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Note the expiration date of the sealing compound.

Fig 7: Cutting Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

Courtesy of AUDI OF AMERICA, LLC

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

-- Rotate the guide frame again.

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

Courtesy of AUDI OF AMERICA, LLC

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

• Thickness of sealant beads: 2.0 mm.

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

• Thickness of sealant beads: 2.5 mm.

-- Place the guide frame on the cylinder head.

Fig 9: Identifying T40116

Courtesy of AUDI OF AMERICA, LLC

-- Install the Locating Pins T40116 into the guide frame and cylinder head.

-- Tighten the camshaft guide frame bolts, refer to Figure.

Fig 10: Guide Frame Bolt, Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

-- Clean the external sealing head holes in the left and right cylinder heads of oil and grease.

Fig 11: 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 Pins T40116 with the Injector/Combustion Chamber Seal Tool Set - Impact Puller T10133/3.

Fig 12: Removing T40116 Using T10133/3

Courtesy of AUDI OF AMERICA, LLC

Install in reverse order of removal. Note the following:

-- Install the high pressure pump motor housing and the high pressure pump, refer to HIGH PRESSURE PUMP .

-- Position the camshaft timing chain on the camshafts, refer to CAMSHAFT TIMING CHAIN, REMOVING FROM CAMSHAFTS .