AUDI A3 1998 8L / 1.G AEB ATW Engines Cylinder Head Remove And Install Workshop Manual

15-2


Cylinder head, removing and
installing

Note:

Replace cylinder head bolts.
Always replace self-locking nuts, bolts as well
as gaskets and O-rings.
After installing a replacement cylinder head with
camshafts attached, grease contact surfaces
between valve lifters and cam lubricating
surfaces.
Do not remove plastic covers protecting
exposed valves until immediately before
installing cylinder head.
When replacing the cylinder head or cylinder
head gasket, coolant must be completely
replaced.
Cylinder heads with small cracks between the
valve seats that are less than 0.3 mm (0.012
in.) wide and/or between one valve seat and
only the first 4 threads of the spark plug thread,
can continue to be used without reduced
service life.
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15-3


Part I

1 -
Cylinder head gasket Replacing page 15
-20
cylinder head,
removing
Installed position: part number faces
cylinder head After replacing, replace coolant
2 -
Cylinder head Removing Page 15
-20
Check for distortion Page 15
-8 , Fig.
1
Refacing measurement Page 15
-8 , Fig.
2

Installing Page 15
-25
After replacing, replace coolant
3 -
Oil deflector Verify correct installation position above
intake camshaft between cylinders 1 and 2
4 -
Cylinder head bolt Always replaceFollow sequence of removal Page 15
-20
Follow torque sequence Page 15
-25
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15-4


Repair Manual, 1.8 Liter 5V Turbo Fuel Injection
& Ignition, Repair Group 28 5 -
Gasket
For ignition coilReplace if damaged
6 -
Ignition Coil Check
7 -
Bolt
10 Nm (7 ft lb)
8 -
Oil filler cap
9 -
Gasket Replace if damaged or leaking
10 -
Nut 10 Nm (7 ft lb)
11 -
Cylinder head cover Removing and installing Page 15
-17
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15-5


CAUTION!
Part numbers are listed here for reference only.
Always check with your Parts department for
the latest information. 12 -
Cylinder head cover gaskets
Replace if damaged or leakingBefore installing, seal contact surfaces with
sealant D 454 300 A2 Fig. 3
and
Fig. 4

13 -
Coolant flange
With coolant temperature sensor
14 -
Bolt 10 Nm (7 ft lb)
15 -
O-Ring Always replace
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ylinder head, removin
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15-6


Part II

1 -
Gasket Always replace
2 -
Nut 10 Nm (7 ft lb)
3 -
Socket-head bolt 10 Nm (7 ft lb)
4 -
O-Ring For injectorAlways replace
5 -
Fuel rail With injectors
6 -
Upper coolant line
7 -
Socket-head bolt 10 Nm (7 ft lb)
8 -
Bolt 10 Nm (7 ft lb)
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15-7


9 -
O-Ring
For upper coolant lineAlways replace
10 -
Socket-head bolt 10 Nm (7 ft lb)
11 -
Intake plenum Removing and installing Page 15
-10
12 -
Socket-head bolt
20 Nm (15 ft lb)
13 -
Brace For intake manifold
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ylinder head, removin
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15-8


Fig. 1 Check cylinder head for distortion
- Using straightedge and feeler gauge, check cylinder head for distortion
at multiple points.
Cylinder head distortion must not exceed 0.1 mm (0.004 in.)

Refacing cylinder head can only be done to a minimum dimension -a-. Fig. 2 Refacing cylinder head
Minimum dimension -a-: 139.25 mm (5.482 in.)
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ylinder head, removin
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15-9


Fig. 3 Sealing contact surfaces between double bearing cap and
cylinder head
- Using small screwdriver, carefully apply thin layer of sealant D 454 300
A2 to both corners of sealing surface between double bearing cap and
cylinder head (arrows).

Fig. 4 Sealing contact surfaces between hydraulic chain
tensioner and cylinder head
- Using small screwdriver, carefully apply thin layer of sealant D 454 300
A2 to both corners of sealing surface between hydraulic chain
tensioner and cylinder head (arrows).
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ylinder head, removin
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15-10

Intake manifold, removing and installing


Removing

Note:
All tie wraps opened or cut during removal must
be reinstalled at the same locations.

CAUTION!

BEFORE disconnecting the battery:

Stop the engine.
Be sure the ignition is switched OFF (also
applies when connecting the battery). Failure
to do so may damage the Engine Control
Module (ECM).
Determine the correct coding for the anti-
theft radio.

- Disconnect battery Ground (GND) strap.
- Remove engine covers.
- Drain coolant Page 19
-4 .
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15-11


- Remove hose (arrow) for Leak Detection Pump (LDP) -V144-.
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ylinder head, removin
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