AUDI A4 1997 B5 / 1.G AWM Engine Valve Gear Service User Guide

15-47


Note:
Intake and exhaust valves must not be reworked. Only lapping in is
permitted.
CAUTION! Fig. 1 Valve dimensionsDimension
Intake valve
Exhaust valve
Diameter -a- mm 26.80 to 27.00 29.80 to 30.00
Diameter -b- mm 5.95...5.97 5.94 to 5.95
-c- mm 104.84 to 105.34 103.64 to 104.14


45 45
Worn exhaust valves with sodium filling must not be disposed of
until they have been treated as follows: The valves must be sawn into two sections with a metal saw at a
point between the center of the shaft and the valve head. They
must not come into contact with water while this is done. Then
throw the valves into a bucket of water (not more than ten at a
time). Step back immediately because a chemical reaction occurs
when the sodium filling burns. After this treatment the valves can be disposed of in the normal
way.
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Camshaft axial clearance, checking


Special tools and equipment

Universal dial indicator bracket VW 387Dial indicator
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Test sequence
Perform measurement with hydraulic lifters
removed and with bearing cap at chain sprocket
end and double bearing cap at camshaft
sprocket end installed.

- Attach dial indicator with universal dial indicator
holder VW 387 to cylinder head:

Intake camshaft

Exhaust camshaft
Wear limit for intake and exhaust camshafts.
Axial clearance: no more than 0.20 mm
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15-50


Exhaust camshaft oil seal, replacing

Special tools and equipment

Oil seal extractor 2085
Holding tool 3036
Assembly tool T10071
Socket head fastener T10092
Pin T40011
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Removing

Cylinder head installed
Lock carrier must be in service position
Page 13
-1 .

- Remove engine cover -arrows-.
- Remove upper toothed belt guard Page 13
-35
.
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- Set crankshaft to markings for TDC of No. 1 cylinder by turning central
bolt on crankshaft sprocket in direction of rotation -arrows-.

Note:
Only tension piston of tensioner until pressure piston is secured with pin
T40011. - Attach socket head fastener T10092 into tensioner for toothed belt.
- Take toothed belt off camshaft sprocket.
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- Loosen camshaft sprocket (counter hold with
3036).

- Remove camshaft sprocket.

- To guide oil seal extractor, thread securing bolt for camshaft sprocket -
arrow- into camshaft as far as it will go by hand.
- Adjust inner part of oil seal extractor 2085 two turns (approx. 3 mm)
from outer part and lock in position with knurled screw.

- Lubricate threaded head of oil seal extractor 2085, place it in position
and, exerting firm pressure, screw it into oil seal as far as possible.
- Loosen knurled screw and turn inner part of extractor against camshaft
until oil seal has been extracted.
- Clamp flats of oil seal extractor in vice. Remove oil seal with pliers.
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Installing

Note:
Do not oil sealing lip of oil seal.

- Place guide sleeve T10071/1 onto crankshaft journal.
- Push sealing ring via guide sleeve onto shaft journal.
- Remove guide sleeve.

- Press in sealing ring with pressure sleeve T10071/3 and bolt T10071/4.
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- Install camshaft sprocket.

Note correct installation position: Narrow web of camshaft sprocket
faces outward -arrows- and marking for No. 1 is visible from front.
- Install securing bolt for camshaft sprocket (use counter hold tool 3036).

Note:
If a piston is at TDC the valves could strike the piston when turning the
camshaft. To avoid damage to valves and pistons the pistons must not be
at TDC. - Align markings on camshaft sprocket with marking on cylinder head
cover.
- Align marking on vibration damper with marking on lower part of
toothed belt guard.
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- Install toothed belt (adjust valve timing) Page
13
-44
.

Note:
Observe all instructions on removing and
installing the toothed belt Page 13
-40
.

Tightening torque

Component

Nm
Camshaft sprocket to camshaft 65
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