Removal And Installation: Camshafts

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

Special tools and workshop equipment required

Puller T40001
Retainer 3036
Sealant remover (commercially available)
Sealant.

Removing

NOTE:

Sealing surfaces on guide frame at bottom and on cylinder head at top must not be worked.

Camshaft bearings are integrated in the cylinder head and guide frame. Before removing guide frame, tension on toothed belt must be released.

Replace the camshaft seal and cover when the guide frame is removed.

-- Removing camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

-- Toothed belt, removing. Refer to TOOTHED BELT .

-- Loosen the camshaft toothed belt sprocket bolt with the 3036.

Fig 1: Loosening Bolt For Camshaft Sprocket Using Retainer 3036

Courtesy of AUDI OF AMERICA, LLC

-- Remove the camshaft toothed belt sprocket with the T40001 and the claws T40001/6 and T40001/7.

Fig 2: Identifying Puller T40001, Claw T40001/6 And Claw T40001/7

Courtesy of AUDI OF AMERICA, LLC

-- Remove the rear toothed belt guard bolts -arrows-.

Fig 3: Identifying Rear Toothed Belt Housing And Cylinder Head

Courtesy of AUDI OF AMERICA, LLC

-- Tilt the rear toothed belt guard away from the cylinder head slightly.

-- Loosen the guide frame bolts in the following sequence: -6 to 1-.

Fig 4: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts and carefully remove the guide frame and lay it on a soft surface on the workbench.

-- Remove the camshafts with the drive chain from the cylinder head and lay on a clean surface.

Installing

Tightening specifications, refer to Figure.

NOTE:

Replace guide frame bolts.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of engine.

-- Remove reside on the cylinder head and guide frame with sealant remover (commercially available).

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

-- Make sure all of the roller rocker levers lie on the valve stem ends correctly.

-- Lubricate the running surfaces of both camshafts.

-- Place the drive chain on the chain sprockets for the removed camshaft as follows:

Cams -A- of cylinder 4 must face each other.

Fig 5: Identifying Cams And Notches
Courtesy of AUDI OF AMERICA, LLC
The notches -arrows- on both camshafts must align.
The side surfaces of the notches must be exactly vertical.

-- Place the camshafts in the cylinder head and the chain tensioner together with the drive chain.

-- Check the camshaft "TDC" position again:

Fig 6: Identifying Cams And Notches Installed

Courtesy of AUDI OF AMERICA, LLC

Cams -A- of cylinder 4 must face each other.
The notches -arrows- on both camshafts must align.
The side surfaces of the notches must be exactly perpendicular to the cylinder head.

NOTE:

Note the expiration date of the sealing compound.

-- Cut the tube nozzle at the front marking (nozzle diameter approximately 1.0 mm).

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

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than specified.

-- Apply an even and light bead of sealant in the clean groove on the guide frame.

Fig 8: Identifying Old Sealant On Guide Frame Groove And From Sealing Surfaces

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

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

Fig 9: Identifying Cylinder Head Bolts Tightening Sequence

Courtesy of AUDI OF AMERICA, LLC

-- Check the camshaft "TDC" position:

It must be possible to insert the -T10252- as far as the stop.

Fig 10: Identifying Camshafts Secured Using Camshaft Locator T10252
Courtesy of AUDI OF AMERICA, LLC

NOTE:

Rotate the camshafts back and forth slightly if necessary to insert the -T10252-.

Ignore -arrows-.

-- Remove the -T10252-.

-- Drive the cover VALVETRAIN OVERVIEW in approximately 1 to 2 mm with the thrust piece 3334.

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

CAUTION:

Risk of damaging valves and piston crowns.

If camshafts are being rotated, crankshaft may not rest with any piston at "TDC".
The engine must be no more than warm to touch.

-- Install the camshaft seal. Refer to EXHAUST CAMSHAFT SEAL .

-- Tighten the rear toothed belt guard. Refer to TOOTHED BELT DRIVE OVERVIEW .

-- Insert the fitting key in the camshaft and make sure it is seated correctly.

-- Installing camshaft adjuster. Refer to CAMSHAFT ADJUSTER .

-- Install toothed belt (adjust timing) TOOTHED BELT DRIVE OVERVIEW .