Genuine Audi A3 Camshaft

Audi A3 Camshaft Parts and Q&A

• Camshaft
  06F-109-102-E
  Q: How to remove and refit the camshaft and valve lifter components, including the timing cover, camshaft housing, and fuel lines on Audi A3?

  A:

  In order to remove the components, firstly remove the timing cover, then the Timing Chain, then the camshaft sprockets. To avoid contact of the valves, fit temporarily the crankshaft pulley, screw the pulley bolt tighter, and rotate the crankshaft 45° to the anti-clockwise. This is followed by taking out the exhaust gas recirculation valve and camshaft cover to access the inlet camshaft and disposing the oil seals and acquiring new ones. Disassemble the wiring of the fuel low-pressure sender and high-pressure pump, unbolt the earth cable of the camshaft housing, and assembly the ignition coils and the wiring harness and cable guide. Wrap the fuel line to the high-pressure pump with cloth and unscrew the banjo and union nut and un-connect it. After unscrewing the bolts, unplug the wiring connections of camshaft position sensor, remove the engine oil dipstick, and the lower section of the inlet manifold. Unbolt the lifting eye on the left-hand engine, unscrew the mounting bolts gradually and remove the camshaft housing with camshafts attached to the cylinder head, with or without a mallet. Wipe the sealant off the cylinder head and cover and then remove the small filter and O-ring off the cylinder head and put the roller/rocker arms and hydraulic tappets in an appropriate box to identify them. Trace the location of each camshaft and remove it out of the housing, remembering that the inlet camshaft has an extra cam to drive the high-pressure pump. Wash down the camshafts and housing carefully checking against wear, discolouration or overheating. Check the end float of the camshaft with a DTI gauge, the reading must be within limits, and check the hydraulic tappets and roller/rockers to wear or damage. To refit, lubricate the journals and bearing surfaces of the camshaft, and insert the camshafts in the bores and set them to TDC position. Coat the mating surfaces of the camshaft housing with a thin coat of sealant, lubricate the roller/rocker arms and hydraulic tappets, and re-fits them, and also make sure every arm is properly clipped to the tappets. Install two provisional studs to assist the journey of the camshaft housing onto the cylinder head, dismount the studs, and provide the retaining bolts by hand-tightening in a spiral intermittently. Angle-Install the bolts according to the specifications, then reassemble the left-hand engine lifting eye, inlet manifold lower part and engine oil dipstick. Reconnect wiring to camshaft position sensor, refit the fuel lines, ignition coils and wiring harness and tighten earth cable bolt. Reinstall the wiring back to the fuel low-pressure sender and high-pressure pump, re-install the exhaust gas recirculation valve and cover with new seals of oil and turn the engine 45 degrees clockwise to TDC position, remove crankshaft pulley and finally re-install the timing chain and camshaft sprockets and timing cover.
• Camshaft
  06F-109-101-J
  Q: What steps should be followed for refitting a camshaft seal and ensuring proper installation on Audi A3?

  A:

  Refitting must involve use of new camshaft seal(s) and use of VAG sealant ( D 188 800 A1 or equivalent) to seal the joints between the retaining frame of the camshaft and the cylinder head. Start by taking off the camshaft cover, timing belt and camshaft sprocket then unbolt the inner belt cover. Continuously loosen up the nuts that hold the retaining ladder frame, bolt, and oil seal bearing caps, and the camshaft sprocket and parallel key, in a dithering diagonal order. With the nuts loosened the springs of the valve will force the camshaft into the air. Remain the camshaft retaining frame and camshaft out of the cylinder head at which point the old seals will be removed and replaced with new ones. Check the bearing caps, retaining frame, and bearing sites in the cylinder head have no wear or pitting, and ensure that the holes that supply oil are free. Examine the lobes and journals of the camshaft visually, inspecting them against a surface that provides a reference point (i.e., an object). When the camshaft surfaces turn discolored or blued it could have been overheated as a result of poor lubrication. The camshaft end float can be measured by firstly fitting the frame, temporarily reattaching the camshaft to the cylinder head followed by tightening retaining nuts to the required torque. Measure the end float by means of a DTI gauge, but leave the hydraulic tappets off as much as possible during this measurement. In refitting, make sure that the crankshaft is properly installed to prevent the piston-to-valve contact, and then install hydraulic tappets and roller rocker fingers. Apply clean engine oil to the journals of the camshaft and cylinder head bearings, then take great care in ensuring that the camshaft slides into the correct position with the cam lobes facing No 1 cylinder facing upwards and position a new oil seal. Apply oil to the upper surfaces of the journals of the camshaft bearings of the retaining frame taking care not to drop any oil on the sealing surface. Wipe the mating faces of the cylinder head and retaining frame then place an even bead of sealant in the groove of the lower surface of the retaining frame and tighten it down as soon as it comes into contact with the cylinder head. Install another sealing cap in the transmission end of the camshaft and then tighten the retaining nuts on the bearing cap sequentially in an alternating diagonal pattern followed by the rest of the nuts. Lastly, screw the retaining nuts to the required torque, re-install the camshaft sprocker, tension the timing belt and install the camshaft cover.