Camshaft, Removing And Installing: Installing

WARNING: This page is about a different car, the 2015 Audi S7, 2015 Audi RS 7, 2014 Audi S7, 2014 Audi RS 7, and 2013 Audi S7. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Replace the plain rectangular compression rings.

Replace any bolts that were tightened with an additional turn.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of engine.

Fig 1: Cleaning Sealing Surfaces

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WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Remove the sealant residue on the cylinder head and the camshaft housing -1-, using for example a rotating plastic brush.

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

Fig 2: Identifying Allocation Of Roller Rocker Lever To Cylinders

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CAUTION:

The engine could be damaged.

Pay attention to the allocation of the roller rocker lever to the cylinders.

-- Insert the hydraulic adjuster with the roller rocker lever. Allocation:

Roller rocker lever with wide rollers -arrow 1- belong to the cylinders without cylinder cut-off.
Roller rocker lever with narrow rollers -arrow 2- belong to the cylinders with cylinder cut-off.

-- Oil running surfaces of both camshafts.

-- Place the camshafts in the cylinder head, being careful of their position so the camshaft housing can be laid on top without tension.

Cylinder Bank 1 (Right):

Fig 3: Positioning Camshafts

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Exhaust camshaft
Intake camshaft

The surfaces with the threaded openings -arrows- must face a little towards the left and towards the engine center.
The camshafts almost set themselves into the correct position.

Fig 4: Facing Threaded Openings -Arrows- Towards Left And Towards Engine Center

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CAUTION:

The engine could be damaged.

The camshaft spacers must be brought into the installed position.

-- Bring the camshaft spacers into the installed position -arrows- :

The spacers must be slid respective to the direction of the ends of the camshafts.

Cylinder Bank 2 (Left):

Fig 5: Positioning Camshafts

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Intake camshaft
Exhaust camshaft

The surfaces with the threaded openings -arrows- must face a little towards the right and towards the engine center.
The camshafts almost set themselves into the correct position.

Fig 6: Facing Threaded Openings -Arrows- Towards Right And Towards Engine Center

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CAUTION:

The engine could be damaged.

The camshaft spacers must be brought into the installed position.

-- Bring the camshaft spacers into the installed position -arrows- :

The spacers must be slid respectively towards the center of the camshafts.

Continuation for Both Cylinder Banks:

Fig 7: Identifying Compression Ring Ends -1 And 2-

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-- Check the location of the compressor ring ends.

The compression ring ends -1 and 2- must face upward or downward, and must never face sideways.

-- Clean and insert the oil screen -arrow-.

Fig 8: Cleaning And Inserting Oil Screen -Arrow-

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Fig 9: Bringing Cam Adjustment Actuators Into Installed Position

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CAUTION:

The engine could be damaged.

Bring all of the pins for all of the cam adjustment actuators into the installed position.

-- Press down the cam adjustment actuator pins -arrow- by hand.

The pins for all of the adjusting elements must not be in the outward position.

NOTE:

Note the expiration date of the sealing compound.

Fig 10: Cutting 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 mm).

CAUTION:

Risk of contaminating camshaft bearing with excess sealant.

Do not apply sealant beads thicker than indicated.

Cylinder Bank 1 (Right):

Fig 11: Applying Sealant Beads -1, 2, 3- To Clean Camshaft Housing Surfaces

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-- Apply sealant beads -1, 2, 3- to the clean camshaft housing surfaces as shown in the illustration.

Thickness of sealant beads: 2.5 mm.

Cylinder Bank 2 (Left):

Fig 12: Apply Sealant Beads -1, 2- To Clean Camshaft Housing Surfaces

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-- Apply sealant beads -1, 2- to the clean camshaft housing surfaces as shown in the illustration.

Thickness of sealant beads: 2.5 mm.

Continuation for Both Cylinder Banks:

NOTE:

Install the lower section of the camshaft housing within five minutes of applying the sealant.

-- Lay the camshaft housing on the cylinder head.

NOTE:

Ensure that the camshafts can be inserted in the camshaft housing axial bearing without force.

-- Insert the Locating PinsT40116 into the camshaft housing and cylinder head.

Fig 13: Inserting Locating Pinst40116 Into Camshaft Housing And Cylinder Head

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-- Tighten the bolts for the camshaft housing, refer to Figure.

Fig 14: Identifying Cylinder Head Banks Bolts In Sequence

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NOTE:

The sealant must harden for approximately 30 minutes after installing the camshaft housing.

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

Fig 15: Removing Locating PinsT40116 With Impact PullerT10133/3

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Cylinder Bank 1 (Right):

Fig 16: Attaching Both Camshaft Adjusters Without Camshaft Timing Chains To Cylinder Head And Loosely Screw On Bolts -1, 2-

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-- Attach both of the camshaft adjusters without camshaft timing chains to the cylinder head and then loosely screw on the bolts -1, 2-.

-- Position the Wrench - CamshaftT40269 onto the camshaft adjuster for the right exhaust camshaft and counterhold with a wrench -2-.

Fig 17: Positioning Wrench - CamshaftT40269 Onto Camshaft Adjuster For Right Exhaust Camshaft And Counterhold With Wrench -2-

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-- Tighten the bolt -1- by hand.

-- Turn the exhaust camshaft with the wrench clockwise until the thread for the camshaft clamp is in the lower center of the camshaft housing opening.

-- Tighten the left bolt -left arrow- on the Camshaft Locating ToolT40264/1.

Fig 18: Locating Left Bolt -Left Arrow- On Camshaft Locating Toolt40264/1

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-- Position the Wrench - CamshaftT40269 onto the camshaft adjuster for the right intake camshaft and counterhold with a wrench -2-.

Fig 19: Positioning Wrench - CamshaftT40269 Onto Camshaft Adjuster For Right Intake Camshaft And Counterhold With Wrench -2-

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-- Tighten the bolt -1- by hand.

-- Turn the intake camshaft with the wrench clockwise until the thread for the camshaft clamp is in the lower center of the camshaft housing opening.

-- Tighten the right bolt -right arrow- on the Camshaft Locating ToolT40264/1.

Fig 20: Locating Right Bolt -Right Arrow- On Camshaft Locating Toolt40264/1

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-- Counterhold with the wrench while removing the bolts -1, 2- and then remove the camshaft adjuster.

Fig 21: Removing Camshaft Adjuster

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Cylinder Bank 2 (Left):

Fig 22: Removing Bolts -1 And 2- By Counterholding With Wrench And Wrench - CamshaftT40269

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-- Attach both of the camshaft adjusters without camshaft timing chains to the cylinder head and then loosely screw on the bolts -1, 2-.

-- Position the Wrench - CamshaftT40269 onto the camshaft adjuster for the left intake camshaft and counterhold with a wrench -2-.

Fig 23: Positioning Wrench - CamshaftT40269 Onto Camshaft Adjuster For Left Intake Camshaft And Counterhold With Wrench -2-

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-- Tighten the bolt -1- by hand.

-- Turn the intake camshaft with the wrench counterclockwise until the thread for the camshaft clamp is in the lower center of the camshaft housing opening.

-- Tighten the left bolt -left arrow- on the Camshaft Locating ToolT40264/2.

Fig 24: Locating Left Bolt -Left Arrow- On Camshaft Locating Toolt40264/2

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-- Position the Wrench - CamshaftT40269 onto the camshaft adjuster for the left exhaust camshaft and counterhold with a wrench -2-.

Fig 25: Positioning Wrench - CamshaftT40269 Onto Camshaft Adjuster For Left Exhaust Camshaft And Counterhold With Wrench -2-

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-- Tighten the bolt -1- by hand.

-- Turn the exhaust camshaft with the wrench counterclockwise until the thread for the camshaft clamp is in the lower center of the camshaft housing opening.

-- Tighten the right bolt -right arrow- on the Camshaft Locating ToolT40264/2.

Fig 26: Locating Right Bolt -Right Arrow- On Camshaft Locating Toolt40264/2

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-- Remove the bolts -1 and 2- by counterholding with the wrench and the Wrench - CamshaftT40269. Remove the camshaft adjuster.

Fig 27: Removing Bolts -1 And 2- By Counterholding With Wrench And Wrench - CamshaftT40269

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Continuation for Both Cylinder Banks:

Fig 28: Identifying Crankshaft Turning Tool T40272

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-- Position the Crankshaft Turning ToolT40272 onto the Wrench - 21mm T40263.

-- Attach the adapter to the bolts on the vibration damper.

The semi-round countersink -arrow A- on the Crankshaft Turning ToolT40272 must face the semi-round countersink -arrow B- on the vibration damper.

NOTE:

Ignore the notch on the Crankshaft Turning ToolT40272.

-- Turn the crankshaft to "TDC" in direction of engine rotation -arrow-.

-- If necessary, turn the crankshaft slightly back and forth to insert the Camshaft Locating ToolT40264/3 by hand into the vibration damper opening and all the way into the cylinder block.

Fig 29: Identifying Camshaft Locating ToolT40264/3

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Installation is performed in reverse order of removal, while noting the following:

-- Install the vacuum pipe adjusting element for the turbocharger, refer to OVERVIEW - TURBOCHARGER .

-- Install right coolant pipe, refer to OVERVIEW - COOLANT PIPES .

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

-- Install the high pressure line, refer to HIGH PRESSURE PIPE, REMOVING AND INSTALLING .

-- Install the high pressure pump, refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Install the ignition coils, refer to IGNITION COILS WITH POWER OUTPUT STAGES, 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.