Camshaft, Removing And Installing: Installing

-- 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.

-- 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): 

1. Exhaust camshaft
2. 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.

-- 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): 

1. Intake camshaft
2. 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.

-- 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: 

-- 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.
  Fig 7: Identifying Compression Ring Ends

  Courtesy of AUDI OF AMERICA, LLC

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

-- Press the camshaft adjustment actuator pins down by hand in direction of -arrow-.

• The actuator pins must not be in the outward position.
  Fig 9: Bring the Cam Adjustment Actuators into the Installed Position

  Courtesy of AUDI OF AMERICA, LLC

-- Cut the tube nozzle at the front marking (nozzle diameter: about 2 mm (0.0787 in.)).

Cylinder Bank 1 (Right): 

-- Apply sealant beads -1, 2, 3 and 4- to the clean camshaft housing surfaces as shown in the illustration.

• Sealant bead thickness: 2.5 mm (0.0984 in.).
  Fig 11: Applying Sealant Beads To Clean Camshaft Housing Surfaces - Cylinder Bank 1 (Right)

  Courtesy of AUDI OF AMERICA, LLC

Cylinder Bank 2 (Left): 

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

• Sealant bead thickness: 2.5 mm (0.0984 in.).
  Fig 12: Applying Sealant Beads To Clean Camshaft Housing Surfaces - Cylinder Bank 2 (Left)

  Courtesy of AUDI OF AMERICA, LLC

Continuation For Both Cylinder Banks: 

-- Lay the camshaft housing on the cylinder head.

-- Insert the Locating Pins T40116 into the camshaft housing and cylinder head.

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

-- Remove the Locating Pins T40116 with the impact puller T10133/3.

Cylinder Bank 1 (Right): 

-- 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 - Camshaft T40269 onto the camshaft adjuster for the right exhaust camshaft and counterhold with a wrench -2-.

-- 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 tool T40264/1.

-- Position the Wrench - Camshaft T40269 onto the camshaft adjuster for the right intake camshaft and counterhold with a wrench -2-.

-- 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 tool T40264/1.

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

Cylinder Bank 2 (Left): 

-- 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 - Camshaft T40269 onto the camshaft adjuster for the left intake camshaft and counterhold with a wrench -2-.

-- 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 tool T40264/2.

-- Position the Wrench - Camshaft T40269 onto the camshaft adjuster for the left exhaust camshaft and counterhold with a wrench -2-.

-- 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 tool T40264/2.

-- Remove the bolts -1 and 2- by counterholding with the wrench and the Wrench - Camshaft T40269. Remove the camshaft adjuster.

Continuation For Both Cylinder Banks: 

-- Position the Crankshaft Turning Tool T40272 onto the Wrench - 21 mm T40263.

-- Attach the crankshaft turning tool to the bolts on the vibration damper.

• The semi-round countersink -arrow A- on the Crankshaft Turning Tool T40272 must face the semi-round countersink -arrow B- on the vibration damper.

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

-- If necessary, turn the crankshaft slightly back and forth to insert the camshaft locating tool T40264/3 by hand into the vibration damper opening and all the way into the cylinder block.

The rest of the installation is performed in reverse order of removal, 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 INSTALLING .

-- 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 .