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How to Replace Camshaft End Cap Seal

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Old 08-04-2010, 08:52 PM   #1
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Default How to Replace Camshaft End Cap Seal

99' A6 C5 2.8L Camshaft end cap seal leaking small amount of oil everyday.
TC and valve cover gasket just done not to long ago, new vacuum line, jet suction pump and green valve.
I guess someone did not get the job done right.

My question is can I replace these two end cap seals(078 103 113E) without remove TC and camshaft?

Thanks!
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Old 08-05-2010, 02:53 AM   #2
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If you are referring to the round black, small hockey puck looking caps at the rear of the engine, Yes. You can gently pry these cam plugs out with a small pick or screwdriver. Clean the area well. Press new caps back into place.
Should take all of ten minutes for both.
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Old 08-05-2010, 06:04 AM   #3
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Thanks for the tips.
Should I remove the holding block on top of it?

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Originally Posted by nickcarguy View Post
If you are referring to the round black, small hockey puck looking caps at the rear of the engine, Yes. You can gently pry these cam plugs out with a small pick or screwdriver. Clean the area well. Press new caps back into place.
Should take all of ten minutes for both.
Click the image to open in full size.
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Old 08-05-2010, 06:22 AM   #4
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There was nothing holding mine in place. 2000 A6 Avant , 2.8 . Just a press fit.
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Old 08-05-2010, 06:50 AM   #5
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rear cam caps unbolt, don't they?
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Old 08-05-2010, 07:43 AM   #6
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I suppose some sealant need to apply before seating.
But if nickcarguy got it done by press it in without any leakage.
Then it should be ok.

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rear cam caps unbolt, don't they?
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Old 08-05-2010, 07:44 AM   #7
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Thanks again!

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Originally Posted by nickcarguy View Post
There was nothing holding mine in place. 2000 A6 Avant , 2.8 . Just a press fit.
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Old 08-05-2010, 08:50 AM   #8
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Quote:
Originally Posted by e292644 View Post
I suppose some sealant need to apply before seating.
But if nickcarguy got it done by press it in without any leakage.
Then it should be ok.
NO! Do not apply any sealant. I once applied sealant to one and it popped out while boost leak testing @ 15psi a week later. Comes out that sealant prevented the rubber ribs from "digging in" the metal groove and lubricated otherwise pretty tacky rubber.
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Old 08-05-2010, 09:45 AM   #9
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Interesting, learn something new everyday.
Thanks for the tip!

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NO! Do not apply any sealant. I once applied sealant to one and it popped out while boost leak testing @ 15psi a week later. Comes out that sealant prevented the rubber ribs from "digging in" the metal groove and lubricated otherwise pretty tacky rubber.
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Old 08-05-2010, 12:54 PM   #10
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Default Try this

http://forums.audiworld.com/showthread.php?p=23919460
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Old 08-05-2010, 01:27 PM   #11
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Easy enough for me, parts is on the way!

Thanks for all of the replies!

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Old 08-06-2010, 09:22 AM   #12
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yep, just use a screwdriver to pop them out, clean the hole and plug back in. I really wanted to add sealant when I did mine but, just seems like the natural thing to do but don't, I took the advice of others and sure enough, no problems.
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Old 08-06-2010, 10:30 AM   #13
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Appreciate all your help!
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Old 08-09-2010, 08:53 AM   #14
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Replaced both caps last Saturday morning while the vehicle sitting overnight.
Fairly easy to pop it out. Clean it with Q-tips and carb cleaner. I did applied a very thin layer of high temp silicon lubricant before insert the new caps.
So far no sign of oil leak.

Again, thanks for all of the replies!
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Old 08-09-2010, 10:40 AM   #15
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Quote:
Originally Posted by e292644 View Post
Replaced both caps last Saturday morning while the vehicle sitting overnight.
Fairly easy to pop it out. Clean it with Q-tips and carb cleaner. I did applied a very thin layer of high temp silicon lubricant before insert the new caps.
So far no sign of oil leak.

Again, thanks for all of the replies!
Applying the silicone is a mistake. I did that and a cap popped out while pressure testing the crankcase at 15psi, well below my normal boost of 23psi... So... beware of cap getting loose and shooting out of the engine.
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Old 06-18-2011, 03:12 AM   #16
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Default Pants on fire!!!!

Hey guys, I thought I'd share my experience of replacing the cap in my 1994 Audi 80 (2.6L V6). It took me 2 hours!!! The major problem was getting the old cap out - there was not enough clearance to get even a very small screwdriver in so I had to hammer a large screwdriver through the cap at a very acute angle (kept slipping off and scraping off the rubber coating because the angle was poor due to a lack of clearance). Once I pierced the old cap, it was still a heck of an effort to lever it out. I had to find my strongest screwdriver as a few of the other ones looked like they were bending. I eventually got the new cap in by tapping it in about a million tiny taps (lack of clearance again!).
I'll monitor it over the next week or so to see if there are any more leaks. There was quite a leak from it previously, which left a burning smoke smell each morning.
Cheers.
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Old 06-19-2011, 12:30 AM   #17
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Default Freeze it

Make it easier on yourselves and freeze the plug.
it slides in very easy and by the time you go and start the engine it expanded enough to stay in place.
apply a thin layer of a good sealer.
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Old 06-19-2011, 12:32 AM   #18
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Quote:
Originally Posted by thejulex View Post
Applying the silicone is a mistake. I did that and a cap popped out while pressure testing the crankcase at 15psi, well below my normal boost of 23psi... So... beware of cap getting loose and shooting out of the engine.
what were you pressure testing?
intake system for leaks or the engine block?
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Old 06-19-2011, 12:32 AM
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