1997 AUDI A4 APB Engine Valve Gear Service Workshop Manual

15-49

Notes:

Mark the direction of rotation of the toothed belt
with chalk or felt pen before removing. A used
belt can break if it rotates in the wrong direction
when reinstalled.
The toothed belt tensioning element is oil-
damped and can therefore only be compressed
slowly by applying constant pressure.

- Using a hexagon key, turn toothed belt tensioning roller -1- clockwise 8
mm in direction of arrow until tensioning lever -2- compresses
tensioning element -3- sufficiently to enable a 2mm dia. spring pin to be
installed in drilling and in plunger.
- Insert spring pin and release toothed belt tensioning roller.
Use spring pin from 2024 A.
- Insert camshaft clamp 3391 in the securing plates of the two
camshafts.
- Loosen both camshaft bolts and remove approx. 5 turns.
- Take out camshaft clamp 3391.

- Pull off both camshaft sprockets with special tool T40001.
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15-50


- Unbolt rear right toothed belt guard -arrows-.
- Detach intake manifold using special tool 3249.

- Unbolt water line -1- and pull it towards the rear.
- Unbolt bracket -2- from cylinder head.
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15-51


- Detach line -arrow- from cylinder head.
- Detach line -2-.

- Remove turbocharger -arrows-.
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15-52

- Unbolt cylinder head cover.

- Loosen and remove cylinder head bolts in
opposite sequence to tightening sequence using
special tool 3452 (Polidrive).

- Carefully lift off cylinder head.

Note:

Use special tool 3452 together with a normal commercial 10 mm socket
when removing and installing.
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15-53

Installing

Notes:

Do not allow any oil or coolant to remain in the
blind holes for the cylinder head bolts in the
cylinder block.
Install new cylinder head bolts.
Connecting vacuum hoses Page 10
-28
.
When installing a new cylinder head:

- Screw in centering pin for intake manifold.
The cylinder head supplied as a replacement
part can be used on both sides (left or right). But
a sealing cap (core plug) must be installed in the
front end of the cylinder head in each case.

- Coat outside circumference of sealing cap (core
plug) with sealant AMV 188 001 02.

- Using drift VW 295, knock in sealing cap (core plug) until outside rim is
flush with end of chamfer in cylinder head.
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15-54

- Before installing cylinder head in position, turn
crankshaft and camshafts to TDC of No. 3
cylinder.

- Install cylinder head gasket on dowel sleeves.
Marking "oben" (top) or part number must face
towards cylinder head.

- Install cylinder head, insert cylinder head bolts
and tighten finger-tight.

It is not necessary to torque down cylinder head bolts again after repairs
have been completed. - Tighten cylinder head bolts in two stages in sequence shown, as
follows:

Stage 1 = 60 Nm.
Stage 2 = turn a further
1/2 turn (180 ) with a rigid wrench (turning
2 x 90 is also permissible).
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15-55


Tightening torques - 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. Component

Nm
Bolts M6 10
Bolts M8 20
Camshaft bearing caps and camshaft adjuster 10
Exhaust manifold to cylinder head 25
Front exhaust pipe to exhaust manifold 25
Oxygen sensor 50
Spark plugs 25
Toothed belt sprocket to camshaft 55
Intake manifold to cylinder head 10
Cylinder head cover 10
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15-56

Cylinder head, checking for distortion


- Measure at several points with straight-edge.
Maximum permissible distortion: 0.1 mm.
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