AUDI A4 1996 B5 / 1.G APB Engine Valve Gear Service Owner's Guide

15-31


- Unclip solenoid valve for charge pressure control -1-.
- Pull connector off EVAP valve -2-.

- Pull connector off throttle unit -1-.
- Pull connector off charge air sensor -2-.
- Pull off crankcase breather -3-.
- Pull connector off intake air temperature sensor -4-.
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15-32


Note:
Watch position of retaining strips -2-. - Remove pressure lines -1-.

- Remove tensioner -1- for ribbed belt.
- Remove toothed belt guards -2- (left and right).
- Remove toothed belt guard -3- (center).
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15-33


Note:
Turn over the engine at the central bolt on the crankshaft. - Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.
- Check position of camshafts: larger holes in securing plates on
camshaft sprockets must align opposite one another on inside. If this is
not the case, turn crankshaft one revolution further.
- Remove sealing plug from cylinder block, left.
TDC drilling in the crankshaft must be visible (or able to be felt) in line
with the sealing plug hole.

- Screw clamping bolt 3242 for crankshaft into sealing plug hole and
tighten.
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15-34


Note:
The central bolt does not have to be loosened to remove the vibration
damper. - Remove vibration damper on crankshaft.

- Remove idler wheel for ribbed belt -arrows-.
- Remove toothed belt guard behind vibration damper -arrows-.
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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.
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15-36


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

- Unbolt cylinder head lifting bracket with coolant line -arrows- from
cylinder head.
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15-37


- Unbolt water line -1- and pull it towards the rear.
- Unbolt bracket -2- from cylinder head.
- Remove heat sensor -2-.

- Unbolt turbocharger -1- from exhaust manifold (3 bolts).
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15-38


Note: - Unbolt coolant line at front of cylinder head -arrows-.
- 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.

Use special tool 3452 together with a normal commercial 10 mm socket
when removing and installing.
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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.
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15-40

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

- Install cylinder head gasket on dowel sleeves.
The 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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