belt AUDI A6 1997 C5 / 2.G AEB ATW Engines Valvetrain Servicing Workshop Manual

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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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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15-46


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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15-49


Note:
When installing ribbed belt, make sure it is seated correctly on the pulleys.
Tightening torques - Using 3241/3 camshaft fitting tool and 3241/1 pressure sleeve, press
oil seal in to stop.
- Install Camshaft Position (CMP) sensor -G40- Page 15
-38
.
- Install upper toothed belt cover.
- Install ribbed belt and ribbed belt tensioner Page 13
-15
.
Component
Tightening
torques
Shutter wheel for Camshaft Position (CMP) sensor -
G40- to camshaft 25 Nm (18 ft lb)
Housing for Camshaft Position (CMP) sensor -G40-
to cylinder head 10 Nm (7 ft lb)
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15-50

Camshafts and hydraulic chain
tensioner, removing and installing


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

Special tools and equipment

3036 retainer
3366 bracket-tensioner

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 engine
rotation to TDC Cyl. 1 marking (arrows).
- Remove cylinder head cover Page 15
-17
.
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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.
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15-51


- Loosen tensioner (arrows) and remove toothed belt from camshaft
gear.
- Use 3036 retainer to loosen camshaft gear.
- Remove camshaft gear.
- Remove housing for Camshaft Position (CMP) sensor -G40-.
- Remove shutter wheel for Camshaft Position (CMP) sensor -G40-.

CAUTION!
If over-tightened, the chain tensioner will be damaged. - Secure hydraulic chain tensioner using 3366 bracket-tensioner.
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15-58


Note:
When turning camshaft, crankshaft must not be at TDC Cyl. 1 for any
cylinder. Valves and/or pistons may be damaged.
Note:
Follow all procedures for removing and installing toothed belt Page 13
-
29
.
CAUTION!
Note:
When installing ribbed belt, make sure it is seated correctly on the pulleys. - Align marking on camshaft gear with marking on cylinder head cover.
- Align marking on vibration damper with marking on lower toothed belt
cover.
- Install toothed belt (adjust valve timing) Page 13
-32
.
After installing the camshafts, the engine must not be started for
approx. 30 minutes. The hydraulic valve lifters have to settle
(otherwise valves will strike the pistons). After installing the valvetrain and lifters, carefully rotate the
crankshaft by hand at least 2 full revolutions before starting to be
sure that valves do not strike the pistons.
- Install ribbed belt and ribbed belt tensioner Page 13
-15
.
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15-59

Tightening torques

Component
Tightening
torques
Bearing cap to cylinder head 10 Nm (7 ft lb)
Hydraulic chain tensioner to
cylinder head 10 Nm (7 ft lb)
Shutter wheel for Camshaft
Position (CMP) sensor -G40- to
camshaft 25 Nm (18 ft
lb)
Housing for Camshaft Position
(CMP) sensor -G40- to cylinder
head 10 Nm (7 ft lb)
Ribbed belt tensioner to
mounting bracket 25 Nm (18 ft
lb)
Camshaft gear to camshaft 65 Nm (48 ft
lb)
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