Audi Cars 1999-05

Camshaft, Bearings & Lifters 2

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Removal & Installation



2.8L DOHC Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. On A4 and A6 models, place the hood lock carrier assembly in the service position.
  6.  
  7. Disconnect the battery negative cable.
  8.  
  9. Rotate the engine to Top Dead Center (TDC).
  10.  
  11. Remove or disconnect the following:

    Accessory drive belt
     
    Tooted cam belt
     
    Engine cosmetic covers
     
    Engine lower splash shield
     
    Crankshaft housing ventilation line from the cylinder head cover
     
    Intake air duct
     
    Coolant expansion tank and place aside
     
    Mass Air Flow (MAF) connector
     
    Evaporative Emissions (EVAP) purge regulator and valve
     

  12.  
  13. Rotate the secondary air injection pump duct 45 degrees clockwise.
  14.  
  15. Remove or disconnect the following:

    Air cleaner assembly
     
    Camshaft Position (CMP) sensor housing and shutter wheel
     
    Cylinder head covers
     

  16.  
  17. Install the Camshaft Locator Bar tool 3391 onto the camshaft locking plates.

    Click image to see an enlarged view

    Fig. The camshaft sprockets are held using tool 3391-2.8L DOHC engine

  18.  
  19. 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

    Click image to see an enlarged view

    Fig. The camshaft gears are removed using tool T40001-2.8L DOHC engine

     



    Oil supply lines for the camshaft bearings
     

  20.  
  21. 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.
  22.  
  23. 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.

    Click image to see an enlarged view

    Fig. The notches in the camshaft align with the arrows on the cam journal caps when the camshafts are at TDC-2.8L DOHC engine

  24.  
  25. Make sure the camshafts are at TDC.
  26.  
  27. 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.
  28.  
  29. 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
     

  30.  

To install:

Click image to see an enlarged view

Fig. Replace the rubber/metal gasket for the camshaft adjuster assembly, and apply a thin layer of sealant on the hatched surface as illustrated

  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
     



    Click image to see an enlarged view

    Fig. The camshaft drive chain is installed on the camshaft sprockets 16 drive chain rollers apart-1.8L and 2.8L DOHC engines

  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
     

  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.

    Click image to see an enlarged view

    Fig. Apply sealant to the shaded areas for camshaft bearing caps numbers 1 and 7-2.8L DOHC engines



    Click image to see an enlarged view

    Fig. Apply a thin bead of sealant at the corners of the outer camshaft journals-2.8L DOHC engines

  14.  
  15. Install or connect the following:

    New camshaft oil seal
     
    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

    Click image to see an enlarged view

    Fig. Camshaft belt routing-2.8L DOHC engines

     



    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.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. On 1998-00 models, place the hood lock carrier assembly in the service position.
  4.  
  5. Disconnect the battery negative cable.
  6.  
  7. Rotate the engine to Top Dead Center (TDC).
  8.  
  9. Remove the accessory drive belt.
  10.  
  11. Remove the tooted cam belt.
  12.  
  13. Remove the engine cosmetic covers.
  14.  
  15. Properly relieve the fuel system pressure.
  16.  
  17. Remove the engine lower splash shield.
  18.  
  19. Remove the crankshaft housing ventilation line from the cylinder head cover.
  20.  
  21. Remove the intake air duct.
  22.  
  23. Remove the coolant expansion tank and place aside.
  24.  
  25. Disconnect the Mass Air Flow (MAF) connector.
  26.  
  27. Disconnect the Evaporative Emissions (EVAP) purge regulator and valve.
  28.  
  29. Rotate the secondary air injection pump duct 45 degrees clockwise and remove from the air cleaner housing.
  30.  
  31. Unbolt the air cleaner assembly and remove.
  32.  
  33. Remove the Camshaft Position (CMP) sensor housing and shutter wheel.
  34.  
  35. Remove the cylinder head covers.
  36.  
  37. Install the camshaft locator bar tool No. 3391 or equivalent onto the camshaft locking plates.

    Click image to see an enlarged view

    Fig. The camshaft sprockets are held using tool No. 3391 or equivalent-2.8L engines

  38.  
  39. Loosen the camshaft bolts and back out 5 revolutions.
  40.  
  41. Remove the camshaft locator bar and remove camshaft gears using tool No. T40001, or equivalent.

    Click image to see an enlarged view

    Fig. The camshaft gears are removed using tool No. T40001 or equivalent-2.8L engines

  42.  
  43. Carefully lift out the oil supply lines for the camshaft bearings. Use care to not damage the positioning clips.
  44.  
  45. Secure the camshaft adjuster using the bracket tensioner tool No. 3366 or equivalent. Use care to not over tighten the bracket adjuster as the camshaft adjuster could be damaged.
  46.  
  47. Verify that both camshafts are at Top Dead Center (TDC). The notch on the camshaft behind the cam sprocket should align with the arrows on the camshaft bearing caps.

    Click image to see an enlarged view

    Fig. The notches in the camshaft align with the arrows on the cam journal caps when the camshafts are at Top Dead Center (TDC)-2.8L DOHC engine

  48.  
  49. Make sure the camshafts are at TDC.
  50.  
  51. 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.
  52.  
  53. Remove the camshaft adjuster retaining bolts, leaving the adjuster in place.
  54.  
  55. Remove the camshaft journals numbers 1, 3, and 5 from both cams and journal number 7 from the exhaust camshaft.
  56.  
  57. Working in a diagonal sequence, carefully loosen and remove the cam journal caps numbers 2 and 4.
  58.  
  59. Remove both camshafts together with the camshaft adjuster assembly.
  60.  

To install:

  1. Replace the rubber/metal gasket for the camshaft adjuster assembly, and apply a thin layer of sealant as illustrated.

    Click image to see an enlarged view

    Fig. Replace the rubber/metal gasket for the camshaft adjuster assembly, and apply a thin layer of sealant on the hatched surface as illustrated

  2.  
  3. Install the drive chain on the camshaft sprockets and align the marks made during disassembly.
  4.  
  5. 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 two camshaft sprockets is 16 drive chain rollers.

    Click image to see an enlarged view

    Fig. The camshaft drive chain is installed on the camshaft sprockets 16 drive chain rollers apart-2.8L DOHC engines

  6.  
  7. Use an assistant to place the camshaft adjuster between the camshaft drive chain and install the camshafts and adjuster into the cylinder head.
  8.  
  9. Apply a film of oil to all the camshaft journal surfaces.
  10.  
  11. Tighten the camshaft adjuster to 84 inch lbs. (10 Nm).
  12.  
  13. Use an alternating diagonal pattern and install the camshaft journals numbers 2 and 4 on both camshafts and torque to 84 inch lbs. (10 Nm).
  14.  
  15. Make sure both camshafts align with the TDC marks.
    NOTE
    The notch of the exhaust camshaft is slightly offset inward from the drive chain roller.

  16.  
  17. Apply sealant to the double camshaft bearing cap (number 1) and the outer bearing cap (number 7) at their mating surfaces. Refer to the shaded area in the illustration.

    Click image to see an enlarged view

    Fig. Apply sealant to the shaded areas for camshaft bearing caps numbers 1 and 7-2.8L DOHC Engines

  18.  
  19. Install the remaining camshaft bearing caps and torque to 84 inch lbs. (10 Nm).
  20.  
  21. Install the camshaft bearing oil lines.
  22.  
  23. Remove the cam chain bracket tensioner tool No. 3366 or equivalent.
  24.  
  25. Apply sealant to the corners of the camshaft journal caps and the gasket surface for the head covers.

    Click image to see an enlarged view

    Fig. Apply a thin bead of sealant at the corners of the outer camshaft journals-2.8L DOHC engines

  26.  
  27. Replace the camshaft oil seal and install the camshaft cam belt sprocket and torque the sprocket bolt to 41 ft. lbs. (55 Nm).
  28.  
  29. Install the cylinder head covers and torque the fasteners to 84 inch lbs. (10 Nm).
  30.  
  31. Install the camshaft toothed belt.

    Click image to see an enlarged view

    Fig. Camshaft belt routing-2.8L DOHC engines

  32.  
  33. Install the accessory drive belt.
  34.  
  35. Install the remaining equipment in the reverse order of removal.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. 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
  40.  
  41. Check the oil level before starting the engine
  42.  
  43. Set the clock to the correct time.
  44.  
  45. Enter the radio security code.
    NOTE
    Diagnostic Trouble Codes (DTCs) may be stored when harness connectors are detached.

  46.  
  47. Read the DTCs and clear the fault codes.
  48.  
  49. Adjust the headlights if necessary.
  50.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. On A4 and A6 models, place the hood lock carrier assembly in the service position.
  6.  
  7. Disconnect the battery negative cable.
  8.  
  9. Rotate the engine to Top Dead Center (TDC).
  10.  
  11. Remove or disconnect the following:

    Accessory drive belt
     
    Toothed cam belt
     
    Engine cosmetic covers
     
    Engine lower splash shield
     
    Crankshaft housing ventilation line from the cylinder head cover
     
    Intake air duct
     
    Coolant expansion tank and place aside
     
    Mass Air Flow (MAF) connector
     
    Evaporative Emissions (EVAP) purge regulator and valve
     

  12.  
  13. Rotate the secondary air injection pump duct 45 degrees clockwise.
  14.  
  15. Remove or disconnect the following:

    Air cleaner assembly
     
    Camshaft Position (CMP) sensor housing and shutter wheel
     
    Cylinder head covers
     

  16.  
  17. Install the Camshaft Locator Bar tool 3391 onto the camshaft locking plates.

    Click image to see an enlarged view

    Fig. The camshaft sprockets are held using tool 3391-2.7L and 2.8L DOHC engine

  18.  
  19. 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

    Click image to see an enlarged view

    Fig. The camshaft gears are removed using tool T40001-2.7L and 2.8L DOHC engine

     



    Oil supply lines for the camshaft bearings
     

  20.  
  21. 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.
  22.  
  23. 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.

    Click image to see an enlarged view

    Fig. The notches in the camshaft align with the arrows on the cam journal caps when the camshafts are at TDC-2.7L and 2.8L DOHC engine

  24.  
  25. Make sure the camshafts are at TDC.
  26.  
  27. 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.
  28.  
  29. 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
     

  30.  

To install:

Click image to see an enlarged view

Fig. Replace the rubber/metal gasket for the camshaft adjuster assembly, and apply a thin layer of sealant on the hatched surface as illustrated

  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
     



    Click image to see an enlarged view

    Fig. The camshaft drive chain is installed on the camshaft sprockets 16 drive chain rollers apart-1.8L and 2.7L and 2.8L DOHC engines

  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
     

  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.

    Click image to see an enlarged view

    Fig. Apply sealant to the shaded areas for camshaft bearing caps numbers 1 and 7-2.7L and 2.8L DOHC engines



    Click image to see an enlarged view

    Fig. Apply a thin bead of sealant at the corners of the outer camshaft journals-2.7L and 2.8L DOHC engines

  14.  
  15. Install or connect the following:

    New camshaft oil seal
     
    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

    Click image to see an enlarged view

    Fig. Camshaft belt routing-2.7L and 2.8L DOHC engines

     



    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.  

2.8L SOHC Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Valve cover(s)
     
    Camshaft Position Sensor (CMP) at the left cylinder head
     
    Plug/cover at the right cylinder head
     
    Camshaft timing belt sprocket
     

  4.  
  5. Identify the bearing caps.
    NOTE
    DO NOT allow the bearing caps to become mixed up.

  6.  
  7. Remove or disconnect the following:
    NOTE
    If the valve lifter is to be reused, it must go in the bore from which it was removed.



    Camshaft bearing caps No. 2 and 3
     
    Camshaft bearing caps No. 1 and 4 by loosening them gradually, in a diagonal sequence
     
    Camshaft
     
    Valve lifter
     



    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-2.8L SOHC engine

  8.  

To install:

  1. Install or connect the following:
    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.



    Lifters into their respective bore
     
    Bearing caps No. 1 and 4 in an alternating and diagonal sequence
     
    Bearing caps No. 2 and 3. Torque all bearing cap bolts to 15 ft. lbs. (20 Nm)
     



    Camshaft timing belt sprocket. Torque the bolt to 52 ft. lbs. (71 Nm)
     
    Plug/cover, on the right cylinder head
     
    CMP on the left cylinder head. Torque the bolts to 89 inch lbs. (10 Nm)
     
    Valve cover
     
    Timing belt
     
    Negative battery cable
     

  2.  
  3. 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.
  4.  
  5. Check the oil level before starting the engine.
  6.  
  7. Check and adjust the headlights.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing belt.
  6.  
  7. Remove the valve cover(s).
  8.  
  9. On the left cylinder head, remove the Camshaft Position Sensor (CPS).
  10.  
  11. On the right cylinder head, remove the plug/cover on the head.
  12.  
  13. Remove the camshaft timing belt sprocket.
  14.  
  15. Identify the bearing caps.
    NOTE
    DO NOT allow the bearing caps to become mixed up.

  16.  
  17. Remove the camshaft bearing caps 2 and 3.
  18.  
  19. Gradually and evenly, loosen the nuts for the camshaft bearing caps 1 and 4, in a diagonal sequence.
  20.  
  21. Remove the cam and lift out the valve lifter. If it is to be reused, it must go in the bore from which it was removed.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-2.8L SOHC Engine

  22.  

To install:

  1. Install the lifters into their respective bore.
  2.  
  3. Install bearing caps 1 and 4 in a alternating and diagonal sequence.
  4.  
  5. Install bearing caps 2 and 3, then tighten all bearing caps to 15 ft. lbs. (20 Nm).
    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 two revolutions, to ensure that the valves do not strike the pistons.

  6.  
  7. Install the camshaft timing belt sprocket and tighten the mounting bolt to 52 ft. lbs. (71 Nm).
  8.  
  9. On the right cylinder head, install the plug/cover on the head.
  10.  
  11. On the left cylinder head, install the Camshaft Position Sensor (CPS) and tighten the mounting bolts to 89 inch lbs. (10 Nm).
  12.  
  13. Install the valve cover.
  14.  
  15. Install the timing belt.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. 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
  20.  
  21. Check the oil level before starting the engine
  22.  
  23. Set the clock to the correct time.
  24.  
  25. Enter the radio security code.
    NOTE
    Diagnostic Trouble Codes (DTCs) may be stored when harness connectors are detached.

  26.  
  27. Read the DTCs and clear the fault codes.
  28.  
  29. Check and adjust the headlights.
  30.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Valve cover(s)
     
    Camshaft Position Sensor (CMP) at the left cylinder head
     
    Plug/cover at the right cylinder head
     
    Camshaft timing belt sprocket
     

  4.  
  5. Identify the bearing caps.
    NOTE
    DO NOT allow the bearing caps to become mixed up.

  6.  
  7. Remove or disconnect the following:
    NOTE
    If the valve lifter is to be reused, it must go in the bore from which it was removed.



    Camshaft bearing caps No. 2 and 3
     
    Camshaft bearing caps No. 1 and 4 by loosening them gradually, in a diagonal sequence
     
    Camshaft
     
    Valve lifter
     



    Click image to see an enlarged view

    Fig. Camshaft bearing cap identification-2.8L SOHC engine

  8.  

To install:

  1. Install or connect the following:
    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.



    Lifters into their respective bore
     
    Bearing caps No. 1 and 4 in an alternating and diagonal sequence
     
    Bearing caps No. 2 and 3. Torque all bearing cap bolts to 15 ft. lbs. (20 Nm)
     



    Camshaft timing belt sprocket. Torque the bolt to 52 ft. lbs. (71 Nm)
     
    Plug/cover, on the right cylinder head
     
    CMP on the left cylinder head. Torque the bolts to 89 inch lbs. (10 Nm)
     
    Valve cover
     
    Timing belt
     
    Negative battery cable
     

  2.  
  3. 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.
  4.  
  5. Check the oil level before starting the engine.
  6.  
  7. Check and adjust the headlights.
  8.  

 
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