AUDI A3 1995 8L / 1.G AEB ATW Engines Valvetrain Servicing Owner's Guide

15-57

- Remove 3366 bracket-tensioner.

CAUTION!
Part numbers are listed here for reference only. Always check with
your Parts department for the latest information. - Lightly coat hatched surface of double bearing cap with sealant D 454
300 A2 and install bearing cap (pay attention to alignment bushings).
- Install remaining bearing caps (pay attention to alignment bushings).
- Replace oil seals for intake and exhaust camshafts Page 15
-42
.

- Install camshaft gear.
Note position: thin rib of camshaft gear points outward (arrows) and
TDC Cyl. 1 marking is visible from the front.
- Using 3036 retainer, install camshaft gear retaining bolt.
- Install Camshaft Position (CMP) sensor -G40- Page 15
-38
.
- Install cylinder head cover Page 15
-18
.
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15-58


Note:
When turning camshaft, crankshaft must not be at TDC Cyl. 1 for any
cylinder. Valves and/or pistons may be damaged.
Note:
Follow all procedures for removing and installing toothed belt Page 13
-
29
.
CAUTION!
Note:
When installing ribbed belt, make sure it is seated correctly on the pulleys. - Align marking on camshaft gear with marking on cylinder head cover.
- Align marking on vibration damper with marking on lower toothed belt
cover.
- Install toothed belt (adjust valve timing) Page 13
-32
.
After installing the camshafts, the engine must not be started for
approx. 30 minutes. The hydraulic valve lifters have to settle
(otherwise valves will strike the pistons). After installing the valvetrain and lifters, carefully rotate the
crankshaft by hand at least 2 full revolutions before starting to be
sure that valves do not strike the pistons.
- Install ribbed belt and ribbed belt tensioner Page 13
-15
.
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15-59

Tightening torques

Component
Tightening
torques
Bearing cap to cylinder head 10 Nm (7 ft lb)
Hydraulic chain tensioner to
cylinder head 10 Nm (7 ft lb)
Shutter wheel for Camshaft
Position (CMP) sensor -G40- to
camshaft 25 Nm (18 ft
lb)
Housing for Camshaft Position
(CMP) sensor -G40- to cylinder
head 10 Nm (7 ft lb)
Ribbed belt tensioner to
mounting bracket 25 Nm (18 ft
lb)
Camshaft gear to camshaft 65 Nm (48 ft
lb)
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15-60

Hydraulic valve lifters, checking


Special tools and equipment

Feeler gauge
Wood or plastic wedge

Note:
Hydraulic valve lifters cannot be serviced.
Irregular valve noise when starting engine is
normal.

- Start engine and let run until coolant
temperature reaches at least 80 C (176 F).

- Increase RPM to 2500 for about 2 minutes; if
necessary test drive vehicle.

Note:
If irregular valve noises disappear but then
reappear during drive, replace oil retaining valve.
Oil retaining valve is located in oil filter bracket
Page 17
-6 .
If hydraulic valve lifters are still loud, locate faulty
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valve lifter as follows:

- Remove cylinder head cover Page 15
-17
.

- Turn crankshaft until cams of valve lifters to be
tested point up.
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15-61

Vehicles with manual transmission

- Switch ignition off, shift into fourth gear and push
vehicle forward.

Vehicles with automatic transmission

- Remove noise insulation panel and turn central
bolt of toothed belt gear for crankshaft in
clockwise direction.

- Determine play between cams and valve
lifters.

CAUTION! - Push down on valve lifters using wood or plastic wedge. If 0.20 mm
(0.008 in.) feeler gauge can be inserted between camshaft and valve
lifter, replace valve lifter.
Valve lifter, replacing Page 15
-50
.
After installing the camshafts, the engine must not be started for
approx. 30 minutes. The hydraulic valve lifters have to settle
(otherwise valves will strike the pistons). After installing the valvetrain and lifters, carefully rotate the
crankshaft by hand at least 2 full revolutions before starting to be
sure that valves do not strike the pistons.
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15-62

Valve stem oil seals, replacing


Cylinder head installed

Special tools and equipment
VW653/3 pressure hose
3122B spark plug removal tool
3362 valve spring tool and 3362/1 pressure
piece
3364 valve seat tool
3365 valve stem seat fitting tool

Removing

- Remove camshafts and hydraulic chain
tensioner Page 15
-50
.

- Remove valve lifters and lay aside with camshaft
contact surface facing down. Be careful not to
interchange valve lifters.

-
Using 3122B spark plug removal tool, remove all
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spark plugs.

- Move piston for individual cylinder to Bottom
Dead Center (BDC) position.
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15-63

- Thread VW653/3 pressure hose into spark plug
hole.

Note:
Lightly tap valve spring retainer to loosen stuck
valve keepers.

Intake and exhaust valves have different installation angles in cylinder
head. 3362 valve spring tool can be used in two different positions:
1 - Top position for the center intake valve
2 - Lower position for both outer intake valves and both exhaust valves
3 - Threaded bores with M6 x 25 retaining bolts on the left and right are
used to secure the lower bracket to cylinder head

- Using retaining bolts bolted into tool, secure 3362 valve spring tool to
cylinder head.
- Adjust tool to correct position for corresponding valve.
- Attach pressure hose to compressor.
Minimum pressure: 6 bar (87 psi)
- Using threaded spindle and 3362/1 pressure piece, press valve springs
downward and remove.
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15-64


- Using 3364 valve seat tool, remove valve stem oil seals.
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