AUDI A3 1996 8L / 1.G AEB ATW Engines Cylinder Head Remove And Install Owner's Manual

15-21


- Remove Ground (GND) connection.
- Drain coolant Page 19
-4 .
- Remove intake manifold Page 15
-10
.
- Remove ribbed belt and ribbed belt tensioner Page 13
-15
.

- Remove the following lines/harness connectors:
1 - At Wastegate Bypass Regulator Valve -N75-
2 - At Evaporative Emission (EVAP) Canister Purge Regulator Valve -
N80-
3 - At Power outage stage -N122-
4 - At Mass Air Flow (MAF) sensor -G70-
- Pull off hose connections and remove air cleaner element housing
(arrows).
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15-22


- Disconnect harness connector -1- at Engine Coolant Temperature
(ECT) sensor -G2-/-G62-.
- Disconnect harness connector -2- at temperature sensor II -G18-.
- Unclip all connections from cylinder head and move clear.

- Remove crankcase ventilation line -1-.
- Remove oil supply line at cylinder head -2-.
- Remove heat shield -3-.
- Unbolt turbocharger from exhaust manifold -4-.
- Disconnect coolant hose to heat exchanger at rear of cylinder head,
also detach retaining clamps at connecting flange.
- Remove upper toothed belt cover Page 13
-29
.
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15-23


CAUTION!
Before removing toothed belt, note direction of rotation with chalk or
felt-tip marker. Reversing the direction of rotation of a used belt can
destroy the belt. - Turn crankshaft at central bolt of toothed belt gear in direction of engine
rotation to TDC Cyl. 1 marking (arrows).
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15-24


-
Using Torx wrench T45, loosen toothed belt tensioner (lower arrow).- Push down on toothed belt tensioner.
- Remove toothed belt from camshaft gear.
-
Remove TORX bolt and swing belt tensioner assembly bracket
forward. - Remove cylinder head cover Page 15
-17
.

- Remove cylinder head bolts in sequential order as shown in illustration.
- Remove cylinder head.
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15-25

Cylinder head, installing


Note:

Always replace cylinder head bolts.
Note inner 12-point or Polydrive versions of
cylinder head bolts Page 15
-1 .

Always replace self-locking nuts, bolts, gaskets
and O-rings.
Carefully remove any sealant residue from
cylinder head or engine block repairs. Avoid
any scratches or scoring.
Thoroughly remove all sanding and grinding
residue.
Do not remove new cylinder head gasket from
package until immediately before installing.
Handle gasket with extra care. Silicon layer and
grooved areas can be damaged leading to
leakage.
Pocket holes in engine block for cylinder head
bolts must be free of oil and coolant.
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- Before installing cylinder head, set crankshaft and camshaft to TDC
Cyl. 1 marking (arrows).
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15-26


- Loosen bolts -1- and -2- at turbocharger bracket two turns to reduce
likelihood of any tension while installing cylinder head.

Note: - Install cylinder head gasket.
Pay close attention to pilot pins (arrows) in engine block.Pay attention to installation position marking for cylinder head gasket:
Part number must be visible from intake side.
- Install cylinder head.
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15-27

- Insert cylinder head bolts and hand tighten.

Note:
It is not necessary to re-tighten the bolts.
Note:
Follow all procedures for removing and installing toothed belt Page 13
-
29
. - Tighten cylinder head bolts in sequential order, in two stages:

Step 1 = 60 Nm (44 ft lb)
Step 2 = additional 1/2 turn using rigid wrench (180 is equivalent
to two 90 turns)
- Using new gasket, bolt turbocharger to exhaust manifold and bolt
bracket to engine block Page 21
-24
.
- Install cylinder head cover Page 15
-18
.
- Install toothed belt (adjust valve timing) Page 13
-32
.
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15-28

- Install ribbed belt and ribbed belt tensioner
Page 13
-15
.

Note:
When installing ribbed belt, make sure it is
seated correctly on the pulleys.

- Adjust Accelerator Pedal (AP) cable.

Repair Manual, Fuel Supply System, Repair
Group 20


- Replace coolant Page 19
-6 .

CAUTION!

Be sure the ignition is switched OFF. Failure
to do so may damage the Engine Control
Module (ECM).

- Switch ignition off and reconnect battery Ground
(GND) strap.

- After connecting battery, enter anti-theft code for
radio.

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Radio operating manual
- Using power window switch, raise windows to
stop.

- Operate all power window switches again for at
least one second in "close" direction to activate
"one touch" opening/closing function.

- Set clock to correct time.
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