Audi Workshop Service and Repair Manuals

Special tools,
testers and auxiliary items required

• ◆ Special tool 2064
• ◆ Special tool 2065 A
• ◆ Special tool 3359

• ● Cylinder head installed
• ● Lock carrier must be in service position .

Removing

• ‒ Remove toothed belt => Page 13-19
• ‒ Remove viscous fan (with belt pulley) => Fig., Page 13-13.
• ‒ Install ribbed belt tensioner => Page 13-7.
• ‒ Remove upper toothed belt guard => Page 13-29.
• ‒ Remove cylinder head cover => Page 15-8.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with manual gearbox).

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with automatic gearbox).

• ‒ → Lock camshaft with setting bar 2065 A.
• ‒ Align setting bar as follows:
  Turn arrested camshaft so that one end of setting bar contacts cylinder head. Measure the gap at other end of setting bar using a feeler gauge. Place a feeler gauge corresponding to half the gap between setting bar and cylinder head. Turn camshaft until setting bar contacts feeler gauge. Insert a 2nd feeler gauge of same thickness at other end, between setting bar and the cylinder head.

Vehicles with engine codes 1Z, AFF, AFN, AHU:

• ‒ → Lock injection pump sprocket with setting pin 2064.

Vehicles with engine code AHH:

• ‒ → Lock injection pump sprocket with setting pin 3359.
• ‒ Remove securing bolts -arrows- of injection pump sprocket.

Note:

→ Do not loosen central nut -2- of injection pump sprocket. Otherwise the injection pump basic setting is maladjusted and can no longer be corrected using workshop tools.

All models:

• ‒ Mark direction of rotation of belt with chalk or felt pen.
• ‒ Remove tensioner.
• ‒ Remove idler wheel.
• ‒ Take toothed belt off camshaft sprocket.

Note:

Never use setting bar to counterhold when loosening and tightening camshaft sprocket. Counterhold with 3036.

• ‒ → Loosen securing bolt of camshaft sprocket by 1/2 turn. Release camshaft sprocket from camshaft taper by tapping with a hammer (using a drift through hole of rear toothed belt guard).
• ‒ Remove camshaft toothed belt sprocket.
• ‒ Only remove bearing caps 1, 3 and 5. Loosen bearing caps 2 and 4 alternately and diagonally.

Installing

Installation is carried out in the reverse order, when doing this note the following:

Notes:

• ◆ Renew camshaft oil seal.
• ◆ When installing the camshaft, No. 1 cylinder cams must point upwards.

• ◆ → Before installing bearing caps, note bore offset and determine installation position.

• ‒ Oil camshaft running surfaces.
• ‒ Tighten bearing caps 2 and 4 alternately and diagonally to 20 Nm.
• ‒ Install bearing caps 5, 1 and 3 and also tighten to 20 Nm.
• ‒ Installing toothed belt (adjust valve timing) with engine codes 1Z, AFF, AFN, AHU => Page 13-53.

Notes:

• ◆ Observe all instructions on removing and installing the toothed belt onwards.
• ◆ 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.

• ‒ Install cylinder head cover => Page 15-9.
• ‒ Dynamically check commencement of injection

=> Diesel direct injection and glow plug system (4 cyl.) ä 06.97; Repair group 23; Servicing diesel direct injection system; Dynamically checking and adjusting commencement of injection

=> Diesel direction-injection and glow lamp system (4-cyl.) 07.97 ä; Repair group 23; Servicing diesel direct injection system; Dynamically checking and adjusting commencement of injection

Tightening torque