Audi Workshop Service and Repair Manuals

Notes:

• ◆ Engine is not to be started for approx. 30 minutes after installing camshaft, so as to allow hydraulic valve lifters to settle (valves would otherwise strike piston).
• ◆ After working on valve gear, carefully crank engine through at least 2 revolutions to ensure that no valves make contact on starting.
• ◆ Always replace gaskets and sealing rings.
• ◆ Heed current information on the use of sealants.

=> Parts List

• ◆ Removing and installing tandem pump:

=> Fuel supply - Diesel engines; Repair Group 20

• Cylinder head
• ◆ Checking valve guides => Page 15-85
• ◆ Reworking valve seats=> Page 15-81
• Bearing shell
• ◆ Pay attention to installation position
• ◆ Do not interchange used bearing shells (mark)
• ◆ Make sure tabs are correctly seated in bearing covers and cylinder head
• Camshaft
• ◆ Checking axial clearance=>Page 15-54
• ◆ Removing and installing=>Page 15-61
• ◆ Check radial clearance with Plastigage
  Wear limit: 0.11 mm
• ◆ Run-out: max. 0.04 mm

• Bearing shell
• ◆ Pay attention to installation position
• ◆ Do not interchange used bearing shells (mark)
• ◆ Make sure tabs are correctly seated in bearing covers and cylinder head
• Bearing cap
• ◆ Installation sequence=>Installing camshaft, Page 15-64
• ◆ Seal bearing covers 1 and 5 with sealant =>Fig.15-53
• ◆ Sealant

=> Parts List

• 8 Nm + further 90° (1/4) turn
• ◆ Replace

• 20 Nm + further 90° (1/4 turn.) turn
• ◆ Replace
• ◆ Heed slackening off sequence
  => Page 15-63
• ◆ Heed tightening sequence
  => Page 15-67
• Valve lever shaft
• ◆ Mark
• ◆ Not to be interchanged
• ◆ Heed slackening off sequence
  => Page 15-63
• ◆ Heed tightening sequence
  => Page 15-67
• Washer
• ◆ For cylinder head bolts
• ◆ Insert in cylinder head before mounting bearing covers

• Hydraulic bucket tappet
• ◆ Checking => Page 15-70
• ◆ Removing and installing=>Page 15-73
• ◆ Not to be interchanged
• ◆ Set down with bearing surface downwards
• ◆ Check axial clearance of camshaft before installing => Page 15-54
• ◆ Lubricate contact surface
• Valve cotters
• Upper valve spring plate
• Outer valve spring
• ◆ Remove and install with cylinder head fitted=>Page 15-73
• ◆ Remove and install with cylinder head removed using 2037

• Inner valve spring
• ◆ Remove and install with cylinder head fitted=>Page 15-73
• ◆ Remove and install with cylinder head removed using 2037
• Valve stem seal
• ◆ Replacing => Page 15-73
• Valve guide
• ◆ Checking => Page 15-85
• ◆ If wear limit is exceeded replace cylinder head
• Pump/nozzle unit
• ◆ Removing and installing:

=> TDI fuel-injection and preheating system (4-cyl. pump/nozzle unit); Repair Group 23; Servicing diesel direct injection system; Removing and installing pump/nozzle unit

• Sealing ring
• ◆ Removing and installing=>Page 15-55
• Valves
• ◆ Not to be reworked; only grinding-in permissible
• ◆ Valve dimensions=>Fig.15-53

→ Fig.1    Sealing bearing covers 1 and 5

• ‒ Apply a thin, even coat of sealant to the surfaces -1-.

• ◆ Sealant

=> Parts List

Note:

Make sure no sealant gets into the grooves -arrows- or onto the other surfaces.

→ Fig. 2    Valve dimensions

Note:

Valves are not to be reworked. Only grinding-in is permitted.