Campaign - Camshaft Seal Plug Replacement
Group: 15Number: 05-02
Date: Jun. 23, 2005
Subject:
Replace Camshaft Sealing Plugs (IE)
Model(s):
A4, A6 with 3.2L (Engine code BKH) 2005 -->
see table below
Tip:
This Technical Bulletin is in effect for 15 months from date of publication as listed above. After that date, this Technical Bulletin will expire and no longer be in effect.
Condition
Service
Requirements:
Vehicle must meet ALL of the following criteria.
1- Procedure is valid only for vehicles that show the IE code in the OTIS view Campaign inquiry screen on the day of repair.
2 - Vehicle must be within the Limited New Vehicle Warranty.
3 - Procedure must be performed within the allotted time frame stated in this Technical Bulletin.
Tip:
Procedure must also be performed on applicable vehicles in Dealer inventory
Procedure:
Replace and Reseal the Camshaft Sealing Caps as described in the following procedure:
Tip:
Bank 1: Only the hole on the intake side (Arrow A) is closed with the Cap.
On the exhaust side the vacuum pump is mounted.
Bank 2: Both holes must be closed with the Cap. The hole of the exhaust camshaft (Arrow C) is difficult to reach because it is located behind the coolant hose.
Sealing Caps A&B need to be Removed and Replaced by a NEW part with additional Sealant.
Tip:
The Sealing Caps have a little borehole exactly in the center under the rubber coating.
- Poke a hook tool, such as a Snap-on(R) 3ASHA or 3ASH90A (see picture), through rubber coating in centers of Cap A and B and pull caps out of the cylinder head.
- Remove Sealing Caps A and B from each borehole.
Bond NEW Sealing Caps Part No:
06B 103 113C in boreholes A and B as follows:
- Clean surfaces of both boreholes. Borehole surfaces must be free of any oil.
Using Loctite(R) 5910 (Part No: ZAW 269 910)
- Apply a 2-3mm wide Sealant Bead all around the outside of the NEW sealing cap as shown.
- Install NEW caps flush in each hole within less than 3 minutes after applying the sealant on cap.
Tip:
Use a flat tool, such as a Snap-on(R) CSA8C gasket scraper (see picture), to push the Sealing Caps into bore holes in order not to push them all the way inside cylinder head.
- After installation, clean up glue residue from outside of caps.
Tip:
The open side of the cap is pointing inside the cylinder head.
In order NOT to remove the coolant hose located in front of Bank 2, the Sealing Cap C does not need to be replaced.
Only Reseal Sealing Cap C as follows:
Manually apply a Sealant Bead outside the sealing cap on the groove between cap and borehole (Use Rubber Gloves).
- Go as far as possible around the cap and cover the entire groove with sealant (see picture).
If all 3 Camshaft Sealing Caps are resealed and Diagnostic Trouble Codes exist:
- Check the engine for existing air leaks. (see Repair Manual and Guided Fault Finding for the vehicle you are working on).
Required Vehicle Update Technical Bulletin Time Requirements/Reimbursement
To ensure prompt and proper payment, be sure to enter, immediately upon completion of the repair work, the applicable reimbursement code listed below.
Claims will only be paid for vehicles that show the IE code in the OTIS View Campaign inquiry screen on the day of repair.
IE Data Entry Procedure Use Claim Type RC
The system automatically enters parts and labor applicable to the above listed code. For vehicles that, according to your information, cannot be corrected or reached, and one of the codes below best describe the reason, please enter one of the applicable codes into the system:
^ IE 20 Customer Refused Repairs
^ IE 30 Total Loss
^ IE 40 Vehicle Stolen
^ IE 50 Vehicle Exported
Additional Required Vehicle Update Technical Bulletins
Some of the affected vehicles may be involved in additional Required Vehicle Update Technical Bulletins. Please check your OTIS View Campaign inquiry screen so that any additional required work can be done simultaneously.
Required Vehicle Update Technical Bulletin Verification
For verification, always check the OTIS View Campaign inquiry screen. The OTIS system is the only binding inquiry and verification system; other systems are not valid and may result in non-payment of a claim.
Help for Claim Input
For questions regarding claim input, contact your appropriate Warranty Claim specialist.
Please do not contact the Campaign Helpline regarding claim input.
Required Customer Notification
Inform your customer in writing by recording on the Repair Order any and all work that was conducted on the vehicle, including any and all updates completed under this Technical Bulletin.