engine oil AUDI A4 1996 B5 / 1.G AHA ATQ Engines Valve Gear Service Manual

15-14

Cylinder head oil seals, replacing


Oil seal for camshaft drive (left and right
cylinder heads)

- Rotate engine to Top Dead Center (TDC).

- Remove toothed belt page 13
-12
.

- Remove rear toothed belt guard.

Note:
Do not apply oil to sealing lip or outer circumference of seal. - Remove seal using 3240 seal extractor.
- Clean contact surface and sealing surface.
- Install 3241/2 pull sleeve from 3241/1 press sleeve onto camshaft.

- Press seal flush into cylinder head using 3241/1 press sleeve and
3241/3 bolt.
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15-16


Rear sealing flange (left cylinder head)
The sealing flange and rear oil seal on the left cylinder head must be
replaced together as follows: - Press seal flush using 3241/1 press sleeve and 3241/3 bolt.
- Unbolt engine coolant expansion tank from bracket.
- Remove crankshaft ventilation line from cylinder head cover.
- Unbolt Camshaft Position (CMP) sensor.
Tightening torque: 10 Nm (7 ft lb)
- Unbolt shutter wheel for Camshaft Position (CMP) sensor G40 and
carefully pry out using screwdriver.
- Remove cylinder head cover.

- Remove double bearing cap (arrows).
- Remove seal and sealing flange.
- Clean running and sealing surfaces as well as contact surface of
double bearing cap.
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15-21


- Disconnect harness connector for tank diagnostic system in engine
compartment at arrow.
- Remove 4 bolts for fuel rail on intake manifold.
- Unclip fuel supply and return lines from retainer.
- Move fuel rail together with fuel injectors aside. Cover fuel injectors
with clean cloth.
- Install 3391 camshaft locator bar onto camshaft locking plates.
- Loosen both bolts for camshafts and back out bolts approx. 5 turns.
- Remove 3391 camshaft locator bar.

- Remove camshaft gear using T40001 special tool.
- Disconnect left-side spark plug connectors.
- Unbolt bracket for ignition coils (4 bolts) and move to right side together
with ignition coils.
- Unhook accelerator pedal cable and pull up out of retaining bracket.
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15-24

Installing

Notes:

Bolt holes in engine block for cylinder head
bolts must be free of oil and coolant.
Always replace cylinder head bolts.
Vacuum line connections page 10-23
When installing a new cylinder head:

- Install centering pin for intake manifold.

- Replacement cylinder head may be used to
replace left or right cylinder head. Install sealing
cap at appropriate front end of replacement
cylinder head.

- Coat lip of sealing cap with sealant AMV 188
001 02.

- Using VW295 needle bearing drift press in sealing cap until lip of cap
seals with chamfer end of cylinder head.
- Before installing cylinder head, set crankshaft and camshafts to TDC
for cylinder 3.
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15-29

Compression, checking


Test conditions

Engine oil temperature at least 30 C

Battery fully charged

- Disconnect harness connectors from all 6 fuel
injectors.

- Disconnect 5-pin harness connector from power
output stage of ignition coils.

- Open throttle fully.

- Use VAG1381 or VAG1763 compression tester
to check compression.

- Operate starter until no further pressure
increases are indicated by VAG1381 or
VAG1763 compression tester.

Compression pressure
New
Wear
limit Max. permissable
difference between
cylinders
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