1999 AUDI A4 oil

15-21

- Install guide sleeve (from tool set 3241) onto
camshaft.

Installing
Install in reverse sequence; note the following points: - Press in oil seal until flush using press sleeve 3241/1 and bolt 3241/3.
- Carefully knock in sealing flange against stop using 3202 and a plastic
hammer.

- 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 21 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

15-24


Installing
Install in reverse sequence; note the following points: - Pull off hose -1-.
- Pull plug connectors off ignition coils.
- Pull crankcase breather off cylinder head cover.
- Remove ignition coils.
- Remove cylinder head cover.

- 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 24 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

15-28

- Remove bolt securing toothed belt guard from
cylinder head cover.

- Unplug connectors from ignition coils.

- Pull crankcase breather off cylinder head
cover.

- Remove ignition coils.

- Remove cylinder head cover.

Installing
Install in reverse sequence; note the following
points.

- 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 28 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

15-30


- Unplug connector for camshaft timing control -1- (cylinder bank 4..6).
- Unplug connectors from injectors -2- (cylinder bank 4..6).
- Unplug connectors from ignition coils -3- and move wiring harness
clear (cylinder bank 4..6).
- Pull crankcase breather -4- off cylinder head cover (cylinder bank 4..6).
- Remove ignition coils.

- Unplug connectors from injectors -2- (cylinder bank 1..3).
- Pull off hose -5- going to turbocharger intake side.
Pa
ge 30 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

15-35

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 the drilling and in the plunger.
- Insert spring pin and release toothed belt tensioning roller.
Use spring pin from 2024 A.
- Insert camshaft clamp 3391 in securing plates of 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.
Pa
ge 35 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

15-39

Installing

Notes:

Do not allow any oil or coolant to remain in the
blind holes for the cylinder head bolts in the
cylinder block.
Replace 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.
Pa
ge 39 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

15-44


- Unplug connectors from injectors -2- (cylinder bank 4..6).

- Unplug connector for camshaft timing control -1- (cylinder bank 1..3).
- Unplug connectors from injectors -2- (cylinder bank 1..3).
- Unplug connectors from ignition coils -3- and move wiring harness
clear (cylinder bank 1..3).
- Pull crankcase breather -4- off cylinder head cover (cylinder bank 1..3).
- Pull off hose -5- going to turbocharger intake side.
- Remove ignition coils.
Pa
ge 44 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

15-49

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.
Pa
ge 49 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