I did a timing belt service on my '03 A4 3.0L last month and when I started it everything seemed fine. The next morning I went out to change the oil, started it and there was a leak. After taking it all apart I came to the conclusion it was one of the cam pulley caps.

I had replaced the cam seals, cap o-rings, and cap clips. This time I replace all the caps (and o-rings) but again the second time I started it there was a leak. It appears to be coming from the caps (not the seals) because the oil is on the front of the pulleys and not the back.

Any ideas or help would be appreciated I'm getting tired of doing this job (third time in 4 months). But I am getting pretty good at it

Thanks in advanced.

 

Ok, I feel stupid now, though I wasn't the only one that missed it when trying to figure it out and I was the one who did figure it out. I didn't really want to post this response but figured it might help someone who does the same thing.

Since parts, tools, and time hindered my timing belt change it was about a month before I was able to complete the process I started. What happened was the cam pulley caps have a little ring that locks the sealing cap in place.

PUT THE CAP IN BEFORE THE LOCKING RING!

It looks fine if done in reverse because the base of the cap is flush with the pulley and it does seal most of the oil (hence it didn't leak till the second run). But it's not quite right and will not work, imagine that.

 

Cool.