light AUDI A3 1999 8L / 1.G AEB ATW Engines Valvetrain Servicing Workshop Manual

15-35


12 -
Bearing cap for intake camshaft
Must fit on bushingBushings must be installed in cylinder headVerify correct installation positionInstallation sequence Page 15
-50
13 -
Double bearing cap
Must fit on bushingBushings must be installed in cylinder headBefore installing, seal contact surfaces
lightly with sealant D 454 300 A2 Page 15
-57

Sealing contact surfaces between double
bearing cap and cylinder head Page 15
-
9 , Fig. 3

14 -
Exhaust camshaft
Using Plastigage check radial play (valve
lifters removed)
Wear range: 0.1 mm (0.004 in.)
Max. run-out: 0.01 mm (0.0004 in.)Axial play, checking Page 15
-41
Camshafts, removing and installing
Page 15
-50

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Installing - Grease threaded head of 2085 seal puller, attach and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.
- Clamp 2085 seal puller in vise at flat surfaces. Remove oil seal using
pliers.
- Lightly oil lip of oil seal.

- Place 3241/2 guide sleeve on end of camshaft.
- Slide oil seal over guide sleeve.
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Installing - Grease threaded head of 2085 seal puller, attach and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.
- Lightly oil lip of oil seal.

- Place 3241/2 guide sleeve on end of camshaft.
- Slide oil seal over guide sleeve.
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- Verify that camshafts are at TDC Cyl 1.

Both camshaft markings must align with arrows on bearing caps.
- Clean drive chain and camshaft chain gears opposite both arrows on
bearing caps. Mark installed position using paint.

Note:
Do not mark chain using punch, filing a notch or similar procedures.
The distance between the two arrows/paint marks is equivalent to
16 drive chain rollers.
The notch on the exhaust camshaft is slightly offset inward toward
drive chain roller (arrow-1-).
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Install drive chain on camshaft chain gear as
follows:

- When installing old drive chain, line up paint markings (arrows).


If a new drive chain is installed, distance between notches -A- and
-B- on camshafts must equal the distance between 16 drive chain
rollers. Illustration shows where first and sixteenth drive chain
rollers must be installed on chain gears.
Notch -A- is slightly offset inward toward drive chain roller -1-.
- Slide in hydraulic chain tensioner between drive chain.
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- Verify correct position of both camshafts.


Both camshaft markings must align with arrows on bearing caps
(arrows).


The distance between the two arrows/paint markings is equivalent
to 16 drive chain rollers.
The notch on exhaust camshaft is slightly offset inward toward
drive chain roller -1-.
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- 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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- 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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Installing

CAUTION! - Place plastic sleeve -A- on valve stem to prevent damage to new valve
stem oil seals.
- Lightly oil lip of valve stem oil seal -B-.
- Insert valve stem oil seal into 3365 valve stem seal fitting tool and
carefully slide onto valve guide.
- Remove plastic sleeve.
- Install camshafts Page 15
-53
.
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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