oil AUDI A8 1999 D2 / 1.G AHA ATQ Engines Valve Gear User Guide

15-16


Rear sealing flange (left cylinder head)
The sealing flange and rear oil seal on the left cylinder head must be
replaced together as follows: - Press seal flush using 3241/1 press sleeve and 3241/3 bolt.
- Unbolt engine coolant expansion tank from bracket.
- Remove crankshaft ventilation line from cylinder head cover.
- Unbolt Camshaft Position (CMP) sensor.
Tightening torque: 10 Nm (7 ft lb)
- Unbolt shutter wheel for Camshaft Position (CMP) sensor G40 and
carefully pry out using screwdriver.
- Remove cylinder head cover.

- Remove double bearing cap (arrows).
- Remove seal and sealing flange.
- Clean running and sealing surfaces as well as contact surface of
double bearing cap.
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15-21


- Disconnect harness connector for tank diagnostic system in engine
compartment at arrow.
- Remove 4 bolts for fuel rail on intake manifold.
- Unclip fuel supply and return lines from retainer.
- Move fuel rail together with fuel injectors aside. Cover fuel injectors
with clean cloth.
- Install 3391 camshaft locator bar onto camshaft locking plates.
- Loosen both bolts for camshafts and back out bolts approx. 5 turns.
- Remove 3391 camshaft locator bar.

- Remove camshaft gear using T40001 special tool.
- Disconnect left-side spark plug connectors.
- Unbolt bracket for ignition coils (4 bolts) and move to right side together
with ignition coils.
- Unhook accelerator pedal cable and pull up out of retaining bracket.
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15-24

Installing

Notes:

Bolt holes in engine block for cylinder head
bolts must be free of oil and coolant.
Always replace cylinder head bolts.
Vacuum line connections page 10-23
When installing a new cylinder head:

- Install centering pin for intake manifold.

- Replacement cylinder head may be used to
replace left or right cylinder head. Install sealing
cap at appropriate front end of replacement
cylinder head.

- Coat lip of sealing cap with sealant AMV 188
001 02.

- Using VW295 needle bearing drift press in sealing cap until lip of cap
seals with chamfer end of cylinder head.
- Before installing cylinder head, set crankshaft and camshafts to TDC
for cylinder 3.
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15-29

Compression, checking


Test conditions

Engine oil temperature at least 30 C

Battery fully charged

- Disconnect harness connectors from all 6 fuel
injectors.

- Disconnect 5-pin harness connector from power
output stage of ignition coils.

- Open throttle fully.

- Use VAG1381 or VAG1763 compression tester
to check compression.

- Operate starter until no further pressure
increases are indicated by VAG1381 or
VAG1763 compression tester.

Compression pressure
New
Wear
limit Max. permissable
difference between
cylinders
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15-33

All models

- Remove Camshaft Position (CMP) sensor
housing and shutter wheel.

- Unbolt shutter wheel for Camshaft Position
(CMP) sensor -G40- and carefully pry out using
screwdriver.

Tightening torque: 20Nm (15 ft lb)

- Remove cylinder head cover.

- Install 3391 camshaft locator bar into camshaft
locking plates.

- Loosen both bolts for camshafts and back out
bolts approx. 5 turns.

- Remove 3391 camshaft locator bar.

- Remove both camshaft sprockets using T40001 special tool.
- Using screwdriver, carefully lift out oil lines for camshaft bearing
lubrication from camshaft bearings.
When lifting out oil lines, be careful not to damage positioning clips.
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15-37


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.
Note:
Notch -A- is slightly offset inward toward drive chain roller -1-.
Notes: - Slide in camshaft adjuster between drive chain (second technician
required).
- Install camshafts with drive chain and camshaft adjuster into cylinder
head.
- Oil camshaft journal surface.
Alignment bushings for bearing caps and camshaft adjuster must be
installed in cylinder head. When installing bearing caps, verify marking on cap is readable from
intake side of cylinder head.
- Tighten camshaft adjuster (pay attention to alignment bushings).

- Tighten bearing caps -2- and -4- in alternating diagonal sequence (pay
attention to alignment bushings).
- Install both bearing caps on chain sprockets of intake and exhaust
camshafts.
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15-39


- Lightly coat hatched surface of double bearing cap -1- and bearing cap
-7-...

- ...with sealant D 454 300 A2 and install bearing cap (pay attention to
alignment bushings).
- Install the other bearing caps (pay attention to alignment bushings).
- Replace oil lines for camshaft bearing lubrication and install.
- Replace oil seal for intake and exhaust camshafts page 15
-14
.
- Remove 3366 bracket tensioner.
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15-46


Note:
If irregular valve noise occurs repeatedly during short journeys and
disappears after extended driving, the oil check valves must be replaced
page 17
-9 . - 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.
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15-47

Valve stem oil seals, replacing


Cylinder head installed
Lock carrier in service position page 13
-1

- Remove ribbed belt page 13
-8 .

- Remove toothed belt page 13
-12
.

- Remove camshafts page 15
-31
.

- Remove valve lifters (do not interchange) and
lay aside with contact surface facing down.

- Remove spark plugs.

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

Note:
Lightly tap valve lever to loosen stuck valve
keepers.

Exhaust side

Note:
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15-48


- Attach 2036 adjustable rod (as shown in figure) using M6 x 40 bolts
with large washers.
- Remove valve spring using VW541/1 lever and VW541/5 valve spring
tensioner.
- Remove valve spring and valve spring plate.
- Remove valve stem oil seal using 3047A slide hammer.

- Place plastic sleeve -A- on valve stem to prevent damage to new valve
stem oil seals.
- Lightly lubricate sealing lip with oil.
- Insert valve stem oil seal -B- (without oiling outside of seal) into 3129
seal driver and carefully slide onto valve guide.
- When installing new valve, lightly oil valve stem before installing.
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