1996 AUDI A4 APB Engine Valve Gear Service Workshop Manual

15-80

- Install drive chain on camshaft sprockets as
follows:


When the old chain is being used again, install the chain so that
the paint markings (arrow) are in line.


When a new chain is being installed, the distance between the
notches -A- and -B- on the camshafts must be 16 rollers on the
chain. The illustration shows the exact positions of the 1st and 16th
rollers on the sprockets.
Notch -A- is offset slightly towards the inside in relation to chain
roller -1-.
- Insert camshaft adjuster inside chain (second mechanic required).
- Locate camshafts with chain and camshaft adjuster in cylinder head.
- Oil camshaft bearing surfaces.
Pa
ge 81 of 99 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.15.1

15-81

Notes:

The dowel sleeves for the bearing caps and
camshaft adjuster must be in the cylinder head.
Install the bearing caps so that the markings on
the bearing caps can be read from the inlet side
of the cylinder head.

- Tighten bolts securing chain tensioner (watch
position of dowel sleeves).

- Tighten bearing caps 2 and 4 of inlet and exhaust camshafts
alternately and in diagonal sequence (watch position of dowel sleeves).
- Install two bearing caps next to chain sprockets on inlet and exhaust
camshafts.
Pa
ge 82 of 99 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.15.1

15-82

- Check correct setting of camshafts:


The two markings on the camshafts must be in line with the two
arrows on the bearing caps -arrows-.


The distance between the two arrows on the bearing caps (or
between the paint markings) is 16 rollers on the chain.
The notch on the exhaust camshaft is offset slightly towards the
inside in relation to chain roller -1-.
Pa
ge 83 of 99 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.15.1

15-83


- Prepare shaded areas on double bearing cap -1- and bearing cap -7-.

.... by applying a thin coat of sealant D 454 300 A2 and install bearing
caps (watch position of dowel sleeves).
- Install remaining bearing caps (watch position of dowel sleeves).
- Install new oil feed lines for camshaft bearings.
- Install new oil seals for inlet and exhaust camshafts; installing Page
15
-10
.
- Remove retainer for chain tensioner 3366.
Pa
ge 84 of 99 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.15.1

15-84

Notes:

When new lifters have been installed the engine
must not be started for about 30 minutes. The
hydraulic compensation elements must settle
(otherwise valves will strike pistons). Then turn
crankshaft two full revolutions before starting.
After working on the valve gear, turn over the
engine carefully at least two revolutions by
hand to ensure that none of the valves make
contact when the starter is operated.

- Seal end points of joints between bearing caps and cylinder head.
- Before installing cylinder head cover and gasket, carefully apply a
small quantity of sealant D 454 300 A2 at four end points of sealing
surfaces on cylinder head -arrows-, using a small screwdriver.
Pa
ge 85 of 99 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.15.1

15-85

- Install cylinder head covers Page 15
-22
.

- Install toothed belt Page 13
-4 .

- Install ribbed belt Page 13
-1 .

Tightening torques

Component

Nm
Bolts M6 10

M8 20
Except for the following:
Bearing caps to cylinder head 10
Camshaft adjuster to cylinder head 10
Hall sensor rotor to camshaft 25
Hall sensor housing to cylinder head 10
Camshaft sprocket to camshaft 55
Camshaft bearing cap and camshaft
adjuster 10
Cylinder head cover 10
Pa
ge 86 of 99 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.15.1

15-86

Camshaft axial clearance, checking


- Remove camshafts Page 15
-75
.

- Remove lifters.

- Install camshafts in cylinder head without drive
chain and secure by tightening bearing caps 2
and 4.

- Attach dial gauge to cylinder head with universal dial gauge bracket
VW 387.
- Press camshaft against dial gauge by hand.
- Set dial gauge to -0-.
- Press camshaft away from dial gauge.
- Note reading on gauge:
New
Wear limit
0.05 ... 0.15 mm 0.20 mm
Pa
ge 87 of 99 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.15.1

15-87


Valve dimensions, checking

Note:
Valves must not be reworked. Only grinding-in (lapping) is permitted.
WARNING!
Worn sodium-cooled exhaust valves must be treated as follows
before disposal:
Dimension
Inlet valve
Exhaust valve
a = diameter mm 26.8 ... 27.0 29.8 ... 30.0
b = diameter mm 5.96 ... 5.97 5.94 ... 5.95
c = mm 104.84 ... 105.34 103.64 ... 104.14
=
45 45
Saw the valves into two sections with a metal saw at a point
between the center of the valve stem and the valve head. The
valves must not come into contact with water when this is done.
Then throw the valves into a bucket of water (not more than ten at
a time) and step back, because a chemical reaction occurs when
the sodium filling burns. After this treatment the valves can be
disposed of in the normal way.
Pa
ge 88 of 99 Valve
gear, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.15.1