Audi Cars 1999-05

Camshaft, Bearings & Lifters 1

Print

Description



The camshaft and cylinder hear are precision machined components. Both the camshaft lobes and journals are hardened to provide long service life and reliability. The cylinder head(s) used on the A4 and Passat models are a cast aluminum alloy. The camshaft bearing journals are machined into the cylinder head and Do NOT have replaceable bearings.

The cylinder head camshaft journal bearing caps and journals are align-bored during production of the cylinder head. If removed, they must be reinstalled in exactly the same location and direction from which they were removed. The bearing cap fasteners must be tightened evenly using several steps until the specified torque specification is reached.

The lifters are installed into machined bores in the cylinder head and are located underneath the camshaft and rest on top of the valve and valve spring assembly. The lifters are hydraulic and Do NOT require periodic adjustment. If removed, they must be reinstalled in exactly the same location from which they were removed.

Both the hydraulic lifters and camshaft journals are lubricated by engine oil which is pressure fed via the engine oil pump through a series of oil galleys that are machined into the cylinder head.

Inspection



Degrease the camshaft using a safe solvent. Visually inspect the cam lobes and bearing journals for excessive wear. If a lobe is questionable or a bearing journal scored, the camshaft should be replaced. Check the lobes and journals with a micrometer. Measure the lobes from nose to heel. If all intake or all exhaust lobes Do NOT measure the same, replace the camshaft. If the lobes and journals appear intact, place the front and rear journals in V-blocks. Position a dial indicator on the center journal and rotate the camshaft. If deviation exceeds 0.0004 inch (0.01mm) replace the camshaft.

Removal & Installation




WARNING
The camshaft is relatively brittle and must be removed and installed carefully otherwise it will break.



Click image to see an enlarged view

Fig. Do not overtighten the chain tensioner tool No. 3366 or equivalent, it can be damaged-2.8L DOHC Engines



Click image to see an enlarged view

Fig. To ensure proper installation, matchmark the chain-to-camshaft position-2.8L DOHC Engines



Click image to see an enlarged view

Fig. To ensure a proper seal, be sure to apply sealant to the hatched area-2.8L DOHC Engines

1.8L Engine
  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Place the (hood) lock carrier in the service position. For additional information, please refer to the following topic(s): Body And Trim, Service Position, Front Bumper, Hood Lock Carrier.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Remove the engine trim covers.
  8.  
  9. Remove timing belt upper cover.
  10.  
  11. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at Top Dead Center (TDC).
  12.  
  13. Using Torx® wrench T45, loosen the timing belt tensioner.
  14.  
  15. Push down on the tensioner, and remove the belt from the camshaft gear.
  16.  
  17. Remove the Torx® bolt and swing the tensioner assembly bracket forward.
  18.  
  19. Remove the valve cover.
  20.  
  21. Using retainer tool No. 3036 or equivalent, loosen the cam gear retaining bolt.
  22.  
  23. Remove the camshaft gear.
  24.  
  25. Remove the housing for Camshaft Position (CMP) sensor and shutter wheel.
  26.  
  27. Secure the hydraulic chain tensioner with bracket tensioner tool No. 3366 or equivalent.
  28.  
  29. Verify that the camshafts are at Top Dead Center (TDC) for the No. 1 cylinder. Both camshaft markings must align with arrows on the bearing caps.
  30.  
  31. Clean the drive chain and the cam chain gears opposite both arrows on the bearing caps. Matchmark the installed position using paint.
  32.  


NOTE
The distance between the 2 arrows/paint marks is equivalent to 16 drive chain rollers, and the notch on the exhaust camshaft is slightly offset inward toward the drive chain roller.

  1. Remove the bearing caps 3 and 5 from the intake and exhaust camshafts.
  2.  
  3. Remove the double bearing cap.
  4.  
  5. Remove both bearing caps from the chain gears on the intake and exhaust camshafts.
  6.  
  7. Remove the hydraulic chain tensioner retaining bolts.
  8.  
  9. In an alternating and diagonal sequence, loosen the bearing caps 2 and 4 of the intake and exhaust manifold, then remove.
  10.  
  11. Remove the camshafts with the hydraulic chain tensioner.
  12.  



Click image to see an enlarged view

Fig. Exploded view of the camshaft mounting and related components-1.8L Engine



Click image to see an enlarged view

Fig. Do NOT overtighten the chain tensioner tool No. 3366, or equivalent, it can be damaged-1.8L and 2.8L V6 DOHC Engines



Click image to see an enlarged view

Fig. To ensure proper installation, matchmark the chain-to-camshaft position-1.8L and 2.8L V6 DOHC Engines



Click image to see an enlarged view

Fig. Camshaft bearing cap identification-1.8L Engine



Click image to see an enlarged view

Fig. To ensure a proper seal, be sure to apply sealant to the hatched area-1.8L and 2.8L V6 DOHC Engines

To install:


CAUTION
After installing the lifters or the camshaft(s), the engine must NOT be started for at least 30 minutes. Otherwise the valves could strike the pistons. Rotate the engine by hand, at least 2 revolutions, to ensure that the valves Do NOT strike the pistons.

  1. Replace the rubber/metal chain tensioner gasket and apply sealant to the hatched area, as shown.
  2.  
  3. Install the drive chain on the camshaft as follows:
  4.  
    1. If installing the old chain, align the paint marks with the camshaft marks.
    2.  
    3. If installing a new chain, the distance between the notches 'A' and 'B' on the camshafts must equal the distance between 16 drive chain rollers.
    4.  

  5. Slide the hydraulic chain tensioner between the drive chain.
  6.  
  7. Install the camshafts with the chain tensioner into the cylinder head.
  8.  
  9. Oil the camshaft contact surfaces.
  10.  


NOTE
When installing the bearing caps, verify the markings on the caps are readable from the intake side of the cylinder head.

  1. Tighten the bearing caps 2 and 4 of the intake and exhaust camshafts in an alternating diagonal sequence to 84 inch lbs. (10 Nm).
  2.  
  3. Install both bearing caps on the chain sprockets of the intake and exhaust camshafts and tighten to 84 inch lbs. (10 Nm).
  4.  
  5. Verify the correct positions of the camshafts.
  6.  
  7. Remove the bracket tensioner.
  8.  
  9. Lightly coat the cylinder head mating surface of the double bearing cap with sealant, then install.
  10.  
  11. Install the remaining bearing caps and tighten to 84 inch lbs. (10 Nm).
  12.  
  13. Install the camshaft gear and tighten the retaining bolt to 48 ft. lbs. (65 Nm).
  14.  
  15. Install the Camshaft Position (CMP) shutter wheel and housing cover.
  16.  
  17. Install the valve cover.
  18.  
  19. Align the camshaft gear and the vibration damper with the TDC markings.
  20.  
  21. Install the timing belt.
  22.  
  23. Install the accessory drive belts, then the engine cover.
  24.  
  25. Reinstall the lock carrier.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
  30.  
  31. Check the oil level before starting the engine
  32.  
  33. Set the clock to the correct time.
  34.  
  35. Enter the radio security code.
  36.  


NOTE
Diagnostic Trouble Codes (DTCs) may be stored when harness connectors are detached.

  1. Read the DTCs and clear the fault codes.
  2.  
  3. Adjust the headlights.
  4.  



Click image to see an enlarged view

Fig. Exploded view of the camshaft mounting and related components-1.8L engine

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Turn the ignition switch to the OFF position.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. On A4 models, place the lock carrier into the service position.
  8.  
  9. Remove or disconnect the following:

    Accessory drive belts
     
    Engine covers
     
    Timing belt upper cover
     

  10.  
  11. Turn the crankshaft, in the direction of rotation (clockwise), until the No. 1 cylinder is at Top Dead Center (TDC).
  12.  
  13. Remove or disconnect the following:

    Timing belt tensioner by loosening it using Torx® wrench T45
     
    Belt from the camshaft gear by pushing the tensioner downward
     
    Torx® bolt and swing the tensioner assembly bracket forward
     
    Timing belt
     
    Valve cover
     
    Cam gear retaining bolt by loosening it using retainer tool 3036
     
    Camshaft gear
     
    Camshaft Position (CMP) housing sensor and shutter wheel
     
    Hydraulic chain tensioner by securing it with bracket tensioner tool 3366

    Click image to see an enlarged view

    Fig. Do not overtighten the chain tensioner tool 3366, it can be damaged-1.8L and 2.7L and 2.8L DOHC engines

     

  14.  
  15. Verify that the camshafts are at TDC for the No. 1 cylinder. Both camshaft markings must align with arrows on the bearing caps.
  16.  
  17. Clean the drive chain and the cam chain gears opposite both arrows on the bearing caps. Matchmark the installed position using paint.
    NOTE
    The distance between the 2 arrows/paint marks is equivalent to 16 drive chain rollers and the notch on the exhaust camshaft is slightly offset inward toward the drive chain roller.



    Click image to see an enlarged view

    Fig. To ensure proper installation, matchmark the chain-to-camshaft position-1.8L and 2.7L and 2.8L DOHC engines



    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-1.8L engine

  18.  
  19. Remove or disconnect the following:

    Bearing caps No. 3 and 5 from the intake and exhaust camshafts
     
    Double bearing cap
     
    Both bearing caps from the chain gears on the intake and exhaust camshafts
     
    Hydraulic chain tensioner retaining bolts
     
    Intake and exhaust manifold bearing caps No. 2 and 4 by loosening them in an alternating and diagonal sequence
     
    Camshafts with the hydraulic chain tensioner
     

  20.  

To install:

Click image to see an enlarged view

Fig. To ensure a proper seal, be sure to apply sealant to the hatched area-1.8L and 2.7L and 2.8L DOHC Engines

  1. Replace the rubber/metal chain tensioner gasket and apply sealant to the hatched area, as shown.
  2.  
  3. Install or connect the following:
    NOTE
    If installing the old chain, align the paint marks with the camshaft marks. If installing a new chain, the distance between the notches A and B on the camshafts must equal the distance between 16 drive chain rollers.


    NOTE
    When installing the bearing caps, verify the markings on the caps are readable from the intake side of the cylinder head.



    Drive chain on the camshaft
     



    Hydraulic chain tensioner by sliding it between the drive chains
     
    Camshafts with the chain tensioner lubricated with engine oil into the cylinder head
     



    Intake and exhaust camshafts bearing caps No. 2 and 4. Torque them in an alternating diagonal sequence to 89 inch lbs. (10 Nm).
     
    Both the intake and exhaust camshafts bearing caps on the chain sprockets. Torque the bolts to 89 inch lbs. (10 Nm).
     

  4.  
  5. Verify the correct positions of the camshafts.
  6.  
  7. Remove the bracket tensioner.
  8.  
  9. Install or connect the following:

    Cylinder head-to-double bearing cap mating surface by lightly coating it with sealant. Torque the remaining bearing caps to 89 inch lbs. (10 Nm)
     
    Camshaft gear. Torque the bolt to 48 ft. lbs. (65 Nm)
     
    CMP shutter wheel and housing cover
     
    Valve cover
     

  10.  
  11. Align the camshaft gear and the vibration damper with the TDC markings.
  12.  
  13. Install or connect the following:

    Timing belt
     
    Accessory drive belts and the engine cover
     
    Lock carrier
     
    Negative battery cable
     

  14.  
  15. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
    CAUTION
    After installing the lifters or the camshaft(s), the engine must NOT be started for at least 30 minutes. Otherwise the valves could strike the pistons. Rotate the engine by hand, at least 2 revolutions, to ensure that the valves do not strike the pistons.

  16.  
  17. Check the oil level before starting the engine.
  18.  
  19. Adjust the headlights.
  20.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Remove the front bumper.
  8.  
  9. Place the hood lock carrier assembly in the service position.
  10.  
  11. Disconnect the battery negative cable.
  12.  
  13. Remove or disconnect the following:

    Air cleaner assembly
     
    Accessory drive belt
     
    Tooted cam belt
     
    Cylinder head covers
     
    Camshaft Position (CMP) sensor housing and shutter wheel
     

  14.  
  15. Install the Camshaft Locator Bar tool 3391 onto the camshaft locking plates.
  16.  
  17. Remove or disconnect the following:

    Camshaft bolts by loosening them 5 revolutions
     
    Camshaft locator bar
     
    Camshaft gears using tool T40001
     
    Oil supply lines for the camshaft bearings
     

  18.  


NOTE
Use care to not damage the positioning clips.

  1. Secure the camshaft adjuster using the bracket tensioner tool 3366. Use care to not over tighten the bracket adjuster as the camshaft adjuster could be damaged.
  2.  
  3. Verify that both camshafts are at TDC. The notch on the camshaft behind the cam sprocket should align with the arrows on the camshaft bearing caps.
  4.  
  5. Clean the camshaft sprockets and cam drive chain and make alignment marks on the sprocket and chain in alignment with the top dead center marks.
  6.  
  7. Remove or disconnect the following:

    Camshaft adjuster retaining bolts, leaving the adjuster in place
     
    Camshaft journals No. 1, 3 and 5 from both cams and journal No. 7 from the exhaust camshaft
     
    Camshaft journal caps No. 2 and 4 by working in a diagonal sequence
     
    Camshafts with the camshaft adjuster assembly
     

  8.  

To install:

  1. Install or connect the following:

    Rubber/metal gasket for the camshaft adjuster assembly by applying a thin layer of sealant, as illustrated
     
    Drive chain on the camshaft sprockets by aligning the matchmarks
     

  2.  


NOTE
If a new chain is installed or the marks are no longer visible, install the chain on the camshaft sprockets such that the distance between the 2 camshaft sprockets is 16 drive chain rollers.


NOTE
Use an assistant to place the camshaft adjuster between the camshaft drive chain.

  1. Install or connect the following:

    Camshafts and adjuster into the cylinder head by lubricating them with engine oil. Torque the camshaft adjuster to 89 inch lbs. (10 Nm)
     
    Camshaft journals No. 2 and 4 on both camshafts. Torque the bolts, using an alternating diagonal pattern, to 89 inch lbs. (10 Nm)
     

  2.  
  3. Align both camshafts with the TDC marks.
  4.  
  5. Apply sealant to the double camshaft bearing cap (No. 1) and the outer bearing cap (No. 7) at their mating surfaces. Refer to the shaded area in the illustration.
  6.  


NOTE
The notch of the exhaust camshaft is slightly offset inward from the drive chain roller.

  1. Install or connect the following:

    Remaining camshaft bearing caps. Torque the bolts to 89 inch lbs. (10 Nm)
     
    Camshaft bearing oil lines
     
    New camshaft oil seal
     

  2.  
  3. Remove the cam chain bracket tensioner tool 3366.
  4.  
  5. Apply sealant to the corners of the camshaft journal caps and the gasket surface for the head covers.
  6.  
  7. Install or connect the following:

    Camshaft cam belt sprocket. Torque the bolt to 41 ft. lbs. (55 Nm)
     
    Cylinder head covers. Torque the fasteners to 89 inch lbs. (10 Nm)
     
    Camshaft toothed belt
     
    Accessory drive belt
     
    Remaining equipment in the reverse order of removal
     
    Negative battery cable
     

  8.  
  9. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
  10.  
  11. Check the oil level before starting the engine.
  12.  
  13. Adjust the headlights if necessary.
  14.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Remove the front bumper.
  8.  
  9. Place the hood lock carrier assembly in the service position.
  10.  
  11. Disconnect the battery negative cable.
  12.  
  13. Remove or disconnect the following:

    Air cleaner assembly
     
    Accessory drive belt
     
    Tooted cam belt
     
    Cylinder head covers
     
    Camshaft Position (CMP) sensor housing and shutter wheel
     

  14.  
  15. Install the Camshaft Locator Bar tool 3391 onto the camshaft locking plates.
  16.  
  17. Remove or disconnect the following:
    NOTE
    Use care to not damage the positioning clips.



    Camshaft bolts by loosening them 5 revolutions
     
    Camshaft locator bar
     
    Camshaft gears using tool T40001
     
    Oil supply lines for the camshaft bearings
     

  18.  
  19. Secure the camshaft adjuster using the bracket tensioner tool 3366. Use care to not over tighten the bracket adjuster as the camshaft adjuster could be damaged.
  20.  
  21. Verify that both camshafts are at TDC. The notch on the camshaft behind the cam sprocket should align with the arrows on the camshaft bearing caps.
  22.  
  23. Clean the camshaft sprockets and cam drive chain and make alignment marks on the sprocket and chain in alignment with the top dead center marks.
  24.  
  25. Remove or disconnect the following:

    Camshaft adjuster retaining bolts, leaving the adjuster in place
     
    Camshaft journals No. 1, 3 and 5 from both cams and journal No. 7 from the exhaust camshaft
     
    Camshaft journal caps No. 2 and 4 by working in a diagonal sequence
     
    Camshafts with the camshaft adjuster assembly
     

  26.  

To install:

  1. Install or connect the following:
    NOTE
    If a new chain is installed or the marks are no longer visible, install the chain on the camshaft sprockets such that the distance between the 2 camshaft sprockets is 16 drive chain rollers.


    NOTE
    Use an assistant to place the camshaft adjuster between the camshaft drive chain.



    Rubber/metal gasket for the camshaft adjuster assembly by applying a thin layer of sealant, as illustrated
     
    Drive chain on the camshaft sprockets by aligning the matchmarks
     

  2.  
  3. Install or connect the following:

    Camshafts and adjuster into the cylinder head by lubricating them with engine oil. Torque the camshaft adjuster to 89 inch lbs. (10 Nm)
     
    Camshaft journals No. 2 and 4 on both camshafts. Torque the bolts, using an alternating diagonal pattern, to 89 inch lbs. (10 Nm)
     

  4.  
  5. Align both camshafts with the TDC marks.
  6.  
  7. Apply sealant to the double camshaft bearing cap (No. 1) and the outer bearing cap (No. 7) at their mating surfaces. Refer to the shaded area in the illustration.
    NOTE
    The notch of the exhaust camshaft is slightly offset inward from the drive chain roller.

  8.  
  9. Install or connect the following:

    Remaining camshaft bearing caps. Torque the bolts to 89 inch lbs. (10 Nm)
     
    Camshaft bearing oil lines
     
    New camshaft oil seal
     

  10.  
  11. Remove the cam chain bracket tensioner tool 3366.
  12.  
  13. Apply sealant to the corners of the camshaft journal caps and the gasket surface for the head covers.
  14.  
  15. Install or connect the following:

    Camshaft cam belt sprocket. Torque the bolt to 41 ft. lbs. (55 Nm)
     
    Cylinder head covers. Torque the fasteners to 89 inch lbs. (10 Nm)
     
    Camshaft toothed belt
     
    Accessory drive belt
     
    Remaining equipment in the reverse order of removal
     
    Negative battery cable
     

  16.  
  17. Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
  18.  
  19. Check the oil level before starting the engine.
  20.  
  21. Adjust the headlights if necessary.
  22.  

 
label.common.footer.alt.autozoneLogo