Camshaft, Removing And Installing: Installing

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

Fig 1: Crankshaft Locking Pin T40069

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Secure crankshaft -1- using Crankshaft Locking Pin T40069.

NOTE:

Replace the seals and gaskets.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of engine.

WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Using a rotating plastic brush, remove any remaining sealant from the cylinder head and guide frame.

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

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

Fig 2: Identifying Screen

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-- Oil running surfaces of both camshafts.

-- Insert the camshafts in the guide frame.

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

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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 upward or downward and 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: Positioning Of Camshafts - Threaded Holes Must Face Upward -Arrows-

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

-- Install the Camshaft Clamp T40133 and tighten the bolts -arrows- to 25 Nm.

Fig 5: Camshaft Clamp T40133, Installed

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NOTE:

Note the expiration date of the sealing compound.

Fig 6: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

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-- Cut the tube nozzle at the front marking (nozzle diameter: about 2.0 mm).

-- Rotate the guide frame again.

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

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CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than specified.

-- 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 sealing surfaces on the guide frame as shown in the illustration.

Sealant bead thickness: 2.5 mm

NOTE:

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

-- Place the guide frame on the cylinder head.

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

Fig 8: Identifying Locating Pins T40116

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NOTE:

The sealant must harden for approximately 30 minutes after installing the guide frame.

-- Tighten the guide frame bolts in the sequence -1 to 21-. Refer to Figure.

Fig 9: Guide Frame Bolt Tightening Sequence

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-- Clean the sealing plug hole in the cylinder head. It must be free of oil and grease.

Fig 10: Identifying Sealing Plug

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-- 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 11: Remove The T40116 Using T10133/3

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Install in reverse order of removal. Note the following:

-- Install the camshaft adjustment valves OVERVIEW - CYLINDER HEAD .

-- Install the brake booster vacuum pump. Refer to OVERVIEW - VACUUM PUMP .

-- Install the high pressure pump motor housing and the high pressure pump. Refer to OVERVIEW - HIGH PRESSURE PUMP .

-- Position the camshaft timing chain on the camshafts. Refer to 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.