1999 AUDI A4 oil

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.
Pa
ge 53 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

15-58

Compression, checking


Test requirements:

Engine oil temperature at least 30 C.

Battery fully charged.

- Remove bolts -arrows- and remove engine cover panels -A...C-.

- Remove air duct -arrows-.
Pa
ge 58 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

15-63

- Pull crankcase breathers off cylinder head
covers.

- Pull plug connectors off ignition coils.

- Remove ignition coils.

- Unplug connectors from all 6 injectors.

- Disconnect 5-pin connecter at power output
stage of ignition coils.

- Open throttle fully.

- Use compression tester VAG 1381 or VAG
1763.

- Operate starter until pressure reading on tester
no longer rises.

Compression pressure values

New
Wear
limit Max. permissible difference
between cylinders
9 ... 13
bar 7 bar 3 bar
Pa
ge 63 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

15-64

Installing
Install in reverse sequence; note the following
points.

- install fuse No. 28 (for fuel pump).

- Erase Diagnostic Trouble Code (DTC)
memory.

Note:
Malfunctions will have been stored in the
memory because the connector to the Hall
sensor has been unplugged. Therefore
interrogate and erase the DTC memory after the
test.

Tightening torque

Component
Nm
Ignition coils to cylinder head 10
Spark plugs in cylinder head 30
Pa
ge 64 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

15-77


Make sure that the retaining catches do not break off when levering out
the oil lines. - Pull off both camshaft sprockets with special tool T40001.
- Using a screwdriver, carefully pry oil feed lines for camshaft bearings
out of camshaft bearings.

Note:
Do not over tighten retainer for chain tensioner, otherwise camshaft
adjuster can be damaged. - Secure camshaft adjuster using retainer for chain tensioner 3366.
Pa
ge 78 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

15-80

- 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

15-83


- 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

15-89

- Measure clearance between cam and lifter.

Note:
If irregular valve noise occurs repeatedly during short journeys and
disappears after extended driving, the oil check valves must be replaceed
Page 17
-12
. - Push lifter down with a wooden or plastic wedge. If a 0.20 mm feeler
gauge can then be inserted between camshaft and lifter, replace lifter:
removing and installing camshafts and camshaft adjuster Page 15
-
75

Pa
ge 90 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