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Engine lubrication > < Removing and installing cylinder head

Repairing Valve Gear in 20/103 kW TDI PD Engine

Testing hydraulic bucket tappets
Testing hydraulic bucket tappets
Special tools and workshop equipment required
t  Feeler gauges
t  Wooden or plastic wedge
  Note
t  Hydraulic bucket tappets cannot be repaired.
t  Irregular valve noises when starting engine are normal.
Test sequence
–  Start engine and allow to run until the radiator fan starts. Increase revolutions to about 2500 rpm for 2 minutes and undertake a test drive if necessary.
  Note
If there are irregular valve noises which disappear after a long drive but keep reappearing on short journeys then the oil retaining valve is defective. Fitting location: in the oil filter holder. The oil retaining valve cannot be replaced individually.
If the hydraulic bucket tappets are still loud, determine the faulty hydraulic bucket tappets as follows:
–  Remove cylinder head cover → Chapter.
–  Turn the crankshaft until the cam of the hydraulic bucket tappets to be tested is positioned on top; while doing so push the vehicle forward in 4th gear when ignition is switched off.
   
–  Determine the play between the cams and the bucket tappet:
–  Press down the bucket tappet using a wooden or plastic wedge.
If a 0.20 mm feeler gauge can be slipped between the camshaft and the bucket tappet:
–  Replace hydraulic bucket tappets → Chapter.
  Note
t  After installing the camsaft, the engine must not be started for about 30 minutes. The hydraulic bucket tappets must settle (otherwise valves would strike the pistons).
t  After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valve touches the piston when the engine is started.
  S15-0372

Engine lubrication > < Removing and installing cylinder head