Audi Workshop Service and Repair Manuals

Notes:

• ◆ After installing the camshaft, wait for about 30 minutes before starting the engine. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons).
• ◆ After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.
• ◆ Renew all gaskets and seals.
• ◆ Removing and installing tandem pump:

=> Fuel Supply - Diesel Engines; Repair group 20

• Cylinder head
• ◆ Checking valve guides
  =>Page 15-123
• ◆ Rework valve seats
  =>Page 15-119
• Bearing shell
• ◆ Note installation position
• ◆ Do not interchange used bearing shells (mark).
• ◆ Make sure that the retaining lugs are correctly seated in the bearing caps and the cylinder head
• Camshaft
• ◆ Checking axial play
  =>Page 15-93
• ◆ Removing and installing
  =>Page 15-100
• ◆ Checking radial play with Plastigage
  Wear limit: 0.11 mm
• ◆ Run-out: no more than 0.04 mm

• Bearing shell
• ◆ Note installation position
• ◆ Do not interchange used bearing shells (mark).
• ◆ Make sure that the retaining lugs are correctly seated in the bearing caps and the cylinder head
• Bearing cap
• ◆ Installation sequence => Installing camshaft, Page 15-104
• ◆ Seal bearing caps 1 and 5 with sealant => Fig.15-92
• ◆ Sealants

=> Parts List

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

• 20 Nm + 90° (1/4 turn) further
• ◆ Replacing
• ◆ Note sequence when loosening => Page 15-103
• ◆ Note sequence when tightening => Page 15-107
• Valve lever shaft
• ◆ Mark
• ◆ Do not interchange
• ◆ Note sequence when loosening => Page 15-103
• ◆ Note sequence when tightening => Page 15-107
• Washer
• ◆ For cylinder head bolts
• ◆ Before assembly of bearing caps insert into cylinder head

• Hydraulic bucket tappet
• ◆ Checking => Page 15-110
• ◆ Removing and installing
  =>Page 15-112
• ◆ Do not interchange
• ◆ Store with cam contact surface downwards
• ◆ Before installing check camshaft axial play
  =>Page 15-93
• ◆ Oil contact surface
• Valve cotters
• Upper valve spring bracket
• Exterior valve spring
• ◆ Removing and installing with cylinder head installed
  =>Page 15-112
• ◆ Removing and installing with cylinder head removed with 2037

• Inner valve spring
• ◆ Removing and installing with cylinder head installed
  =>Page 15-112
• ◆ Removing and installing with cylinder head removed with 2037
• Valve stem seal
• ◆ Replacing => Page 15-112.
• Valve guide
• ◆ Checking => Page 15-123
• ◆ When exceeding wear limit replace cylinder head
• Pump jet unit
• ◆ Removing and installing:

=> TDI Injection and Glow Plug System (4-cyl Pump Jet); Repair group 23; Servicing diesel direct injection system; Removing and installing pump-jet unit

• Sealing ring
• ◆ Removing and installing
  =>Page 15-94
• Valves
• ◆ Do not rework only grinding in is permitted
• ◆ Valve dimensions
  => Fig.15-92

→ Fig.1    Sealing bearing caps 1 and 5

• ‒ Apply the sealant thinly and evenly to the surfaces -1-.

• ◆ Sealants

=> Parts List

Note:

Make sure that the sealant does not come in contact with the grooves -arrows- and the other surfaces.

→ Fig. 2    Valve dimensions

Note:

Valves must not be reworked. Only grinding in is permitted.