AUDI A6 1997 C5 / 2.G AEB ATW Engines Valvetrain Servicing User Guide

15-40

WARNING!

Sodium-filled exhaust valves must not be
scrapped without first being properly treated.
The valves must be cut open using a
hacksaw, by hand, between the valve head
and the middle of the stem.
The valves must not come into any contact
with water while being cut.
After cutting open the valves, throw not more
than 10 at a time into a bucket of water and
step back. A sudden chemical reaction will
occur during which the sodium filling is
consumed.
Valves that have been treated in this way can
be disposed of as normal waste.
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15-41

Camshafts axial play, checking


Special tools and equipment

VW387 dial gauge holder
Dial indicator
Measure with installed bearing cap on chain
sprocket side and double bearing cap on
camshaft side with valve lifters removed.

- Secure VW387 dial gauge holder with dial
indicator to cylinder head.

Intake camshaft

Exhaust camshaft
Wear limit for intake and exhaust camshafts:
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Axial play max.: 0.20 mm (0.008 in.)
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15-42

Oil seals for camshafts, replacing


Cylinder head installed
Lock carrier in service position Page 13
-1

Special tools and equipment

2085 seal puller
3241 seal installer
3036 retainer

Replacing exhaust camshaft oil seal

Removing

- Remove ribbed belt and ribbed belt tensioner
Page 13
-15
.

- Remove engine covers.

- Remove upper toothed belt cover Page 13
-
29
.

-
Turn crankshaft at central bolt of toothed belt gear in direction of
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engine rotation to TDC Cyl. 1 marking (arrows).
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15-43

CAUTION!

Before removing toothed belt, note direction
of rotation with chalk or felt-tip marker.
Reversing the direction of rotation of a used
belt can destroy the belt.

- Loosen tensioner (arrows) and lift toothed belt from camshaft gear.
- Use 3036 Retainer to loosen camshaft gear.
- Remove camshaft gear.

- Thread camshaft gear retaining bolt (arrow) into camshaft by hand until
stop to guide 2085 seal puller.
- Unthread inner part of 2085 seal puller two turns (approx. 3 mm or 0.12
in.) and secure using knurled bolt.
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15-44


Installing - Grease threaded head of 2085 seal puller, attach and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.
- Clamp 2085 seal puller in vise at flat surfaces. Remove oil seal using
pliers.
- Lightly oil lip of oil seal.

- Place 3241/2 guide sleeve on end of camshaft.
- Slide oil seal over guide sleeve.
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15-45


- Using 3241/5 camshaft fitting tool and 3241/1 pressure sleeve, press
oil seal in to stop.

- Install camshaft gear.
Note position: thin rib of camshaft gear points outward (arrows) and
TDC Cyl. 1 marking is visible from the front.
- Using 3036 retainer, install camshaft gear retaining bolt.
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15-46


Note:
While turning camshaft, valves could hit pistons that are at TDC. Verify
that no piston is at TDC. Valves and/or pistons may be damaged.
Note:
Follow all procedures for removing and installing toothed belt Page 13
-
29
.
Note:
When installing the ribbed belt, make sure it is seated correctly on the
pulleys.
Tightening torques - Align marking on camshaft gear with marking on cylinder head cover.
- Align marking on vibration damper to that on lower toothed belt cover.
- Install toothed belt (adjust valve timing) Page 13
-32
.
- Install ribbed belt and ribbed belt tensioner Page 13
-15
.
Component
Tightening torques
Camshaft gear to camshaft 65 Nm (48 ft lb)
Ribbed belt tensioner to mounting bracket 25 Nm (18 ft lb)
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15-47

Replacing intake camshaft oil seal

Removing

- Remove ribbed belt and ribbed belt tensioner
Page 13
-15
.

- Disconnect harness connector from Camshaft Position (CMP) sensor -
G40-.
- Remove upper toothed belt cover Page 13
-29
.
- Remove housing for Camshaft Position (CMP) sensor -G40-.
- Remove shutter wheel and washer for Camshaft Position (CMP)
sensor -G40-.

- Insert 2085/1 adapter into camshaft by hand until stop to guide seal
puller.
- Unscrew inner part of 2085 seal puller two turns (approx. 3 mm or 0.12
in.) and secure using knurled bolt.
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