AUDI A4 1996 B5 / 1.G AWM Engine Cylinder Head Remove And Install Owner's Guide

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Cylinder head, installing


Note:

Always replace the cylinder head bolts.
When performing repairs, replace seals,
gaskets, self-locking nuts and bolts which have
a specified tightening angle.
Secure all hose connections with the correct
hose clips (same as original equipment):

Parts List

If repairing, carefully remove any remains of
gasket material from the cylinder head and
cylinder block. Make sure that no long scores or
scratches are made on the surfaces.
Carefully remove any remaining emery and
abrasive material.
Remove new cylinder head gasket from
packaging, just before installation.
Handle gasket extremely carefully. Damaging
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the silicone layer or the indented area will lead
to leaks.
No oil or coolant must be allowed to remain in
the blind holes for the cylinder head bolts in the
cylinder head.

- Before positioning cylinder head, set crankshaft and camshaft to TDC
of cylinder 1.
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- Loosen bolts -1- and -2- on turbocharger bracket (about 2 full turns
each) to avoid stressing when installing cylinder head.

- Place cylinder head gasket in position.

Note position of centralizing pins in cylinder block -arrows-.
Check installation position of cylinder head gasket. The Part No.
should be legible from intake side.
- Position cylinder head.
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15-30

- Insert cylinder head bolts and tighten by hand.

Note:
It is not necessary to retighten cylinder head bolts after repairs have been
performed.
Note:
Observe all instructions on removing and installing the toothed belt
Page 13
-40
. - Tighten cylinder head bolts in two stages in sequence shown as
follows:
- Tighten using torque wrench:

Stage 1: 40 Nm
- Tighten with rigid wrench:
Stage 2: 180 (
1/2turn) further (2 turns of 90 further is
permissible)
- Tighten exhaust turbocharger to exhaust manifold with new seal and
attach bracket to cylinder block Page 21
-45
.
- Install cylinder head cover Page 15
-18
.
- Install toothed belt (adjust valve timing) Page 13
-44
.
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- Install ribbed belt and tensioner for ribbed belt
Page 13
-20
.

- Install intake line Page 15
-13
.

- Replace coolant Page 19
-7 .

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

Radio operating instructions
- Close windows fully using window switches.

- Actuate all power window switches again for at
least one second in the "close" direction to
activate the automatic open/close function.

- Set clock to correct time.

- Perform throttle-valve control module
adaption:

Repair Manual, 1.8 Liter 4
-Cyl. 5V Turbo Fuel
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Injection & Ignition, Engine Code(s): AWM , Repair Group 24

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Tightening torques

Component

Nm
Support for intake
manifold to intake
manifold 20
to bracket 20
Turbocharger to exhaust manifold
35
1)
2)
Turbocharger bracket to cylinder block
25
Turbocharger bracket to turbocharger
30
Hose clamps for coolant hoses
2
Hose clamps for air duct hoses
3.5

1) Replace bolts
2) Coat thread and head attachment area with
high temperature lubricant G 052 112 A3
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Compression, checking


Special tools and equipment

Spark plug spanner 3122 B

Compression tester VAG VAG 1763
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Test conditions:

Engine oil temperature at least 30 C

Battery voltage at least 12.7 V

Test sequence

- Remove engine cover -arrows-.
- Switch ignition off.

- Disconnect connectors -3-.
- Remove ignition coils -1-.
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- Remove spark plugs with spark plug spanner
3122B.

- Disconnect connectors from all injectors.

- Fully open throttle valve.

- Check compression with compression tester
VAG VAG 1763.

Note:
Using the compression tester

Operating instructions
- Operate starter until tester shows no further
pressure increase.

Compression pressure values:

New


Wear limit


Permissible
difference between
cylinders

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