AUDI A4 2000 B5 / 1.G APB Engine Valve Gear Service Service Manual

15-41


Tightening torques - 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. Component

Nm
Bolts M6 10
Bolts M8 20
Camshaft bearing caps and camshaft adjuster 10
Exhaust manifold to cylinder head 25
Front exhaust pipe to exhaust manifold 25
Oxygen sensor 50
Spark plugs 25
Toothed belt sprocket to camshaft 55
Intake manifold to cylinder head 10
Cylinder head cover 10
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15-42

Removing and installing right cylinder head

Notes:

All hose connections are secured with clips.
Charge air system must be free of leaks.
Replace all seals and gaskets

Removing

- Remove engine Page 10
-1 .

- Unplug connector from air recirculation valve -2-.
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- Remove cover panel from right-hand cylinder head cover -arrows-.

Note:
Plug lower section of intake line. - Disconnect hose -1-.
- Disconnect hose -2-.
- Unbolt upper section of intake line -3-.
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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.
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15-45


- 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-.
- Pull connector -5- off Hall sensor.
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15-46


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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15-47


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.
The 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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15-48


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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15-49

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.
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15-50


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

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