Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Counterhold T10051

• ◆ Puller T10052

Removing

• ● Cylinder head fitted
• ● Lock carrier in service position =>Page 13-1.

• ‒ Remove toothed belt => Page 13-36.
• ‒ → Screw out camshaft sprocket bolts -1-.
• ‒ Detach camshaft sprocket from hub.

• ‒ → Slacken hub bolt -1-. Use counterhold T10051.
• ‒ Screw out hub bolt approx. 2 turns.

• ‒ → Position puller T10052 and screw bolts -1- into hub.
• ‒ Detach hub by bracing against hexagon (A/F 30) of puller and screw in bolt -2-.
• ‒ Detach hub from camshaft cone.
• ‒ Remove cylinder head cover => Page 15-10.

• ‒ → Mark the valve lever shafts with a waterproof marker to avoid them being interchanged and consequently having to reset the pump/nozzle unit -arrows-.
• ‒ First slacken the two outer bolts -1- on the valve lever shafts, then the inner bolts -2-.
• ‒ Detach valve lever shafts.
• ‒ Remove tandem pump:

=> Fuel supply - Diesel engines; Repair Group 20

• ‒ → First remove bearing covers 1, 3 and 5. Unfasten bearing caps 2 and 4 alternately and diagonally.

Notes:

• ◆ Take care not to interchange camshaft bearing shells.
• ◆ Use waterproof felt-tip pen to mark assignment of camshaft bearing shells on back.

• ‒ Take out camshaft.

Installing

Install in reverse order, paying attention to the following:

• ● → Crankshaft toothed belt locked at cylinder 1 TDC with crankshaft stop T10050.

Notes:

• ◆ Do not interchange used bearing shells (pay attention to marking).
• ◆ When installing camshaft, make sure tabs of bearing shells are correctly seated in bearing covers and cylinder head.

• ‒ Lubricate camshaft contact surfaces.
• ‒ Mount camshaft at cylinder 1 TDC position:
• ‒ → On the camshaft the cams for cylinder 1 must all point uniformly upwards -arrows-

• ‒ → Tighten bearing caps 2 and 4 alternately and diagonally.

• ‒ → Apply a thin, even coat of sealant to the surfaces -1- of bearing covers 1 and 5.

• ◆ Sealant

=> Parts List

Note:

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

• ‒ → Install bearing covers 1, 3 and 5 in place, and tighten them too.

Note:

Bearing cover 5 must abut flush with the outer edge of the cylinder head, otherwise the tandem pump may leak.

• ‒ Install camshaft oil seal => Page 15-55.

• ‒ → Insert valve lever shafts. Refit to markings made during removal
  -arrows-.
• ‒ First tighten the inner bolts -2- and then the outer bolts -1- in several alternating stages.

• ‒ Mount hub on camshaft.
• ‒ → Tighten bolt -1-, bracing with counterhold T10051.

• ‒ → Push camshaft sprocket onto hub.

Note:

The tooth segment -arrow- of the camshaft sprocket must be at the top.

• ‒ Screw bolts -1- in hand-tight.
• ‒ The camshaft sprocket must just about still turn, and must not tilt.
• ‒ Arrest hub with rig pin 3359.
• ‒ Install toothed belt (adjust valve timing) => Page 13-44.
• ‒ Install tandem pump:

=> Fuel supply - Diesel engines; Repair Group 20-

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.

• ‒ If the valve lever shafts or ball pins and adjuster screws were replaced, you must adjust the pump/nozzle unit:

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

• ‒ Install cylinder head cover => Page 15-12.

Tightening torques

    1)    90°corresponds to quarter of a turn

    2)    Replace bolts