I-5 cam change procedure Q????

[Derek]

> Is there an easy way to change out the cam on an I-5 without removing the
timing belt???
Yes and no.  You don't have to remove the belt from the crank or waterpump,
but you will have to pull it off the cam gear.  Mark the belt and the cam
gear somehow, so you'll know how to reinstall.  I have been able to slip the
belt off and on the cam gear with out disturbing the waterpump.

>I am planning on leaving the cam gear in place and just swapping out the
shaft if possible.
Not really possible.  The cam gear has to come off to get the cam out.
After removing the timing belt cover, I insert a wrench in the gear to jam
it while I loosen the nut.  Don't drop the wudruff key when you take the cam
gear off.
http://www.humanspeakers.com/audi/imageNH2/camlock.jpg (credit's to Huw for
the pic)

> Also, is there a trick to tightening down the cam bearings so that one of
them doesn't break???
I tighten them in stages, from the inside moving outward, just like
tightening head bolts.  give the inner two a couple turns, move to the outer
ones, repeat until seated.  Final torque is 20nm if I remember correctly.
80nm on the cam bolt.  Run for 20 minutes around 2000rpm to let the bearings
get to know each other.

>Had that happen once and the result was not pleasant.
Ouch (sound of wallet hurting)

HTH
-Derek L