engine AUDI A6 1999 C5 / 2.G AEB ATW Engines Cylinder Head Remove And Install User Guide

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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15-29

- Perform throttle valve control module adaptation
to Engine Control Module (ECM).

Repair Manual, 1.8 Liter 5V Turbo Fuel
Injection & Ignition, Repair Group 24
Tightening torques

Component
Tightening
torque
Intake manifold brace to intake
manifold 20 Nm (15 ft
lb)
Intake manifold brace to bracket 20 Nm (15 ft
lb)
Turbocharger to exhaust
manifold 35 Nm (26 ft
lb)
Turbocharger bracket to
turbocharger (bolt and washer
assembly M8) 40 Nm (30 ft
lb)

Turbocharger bracket to cylinder
block 45 Nm (33 ft
lb)
Retainer straps for oil supply line
to cylinder head 20 Nm (15 ft
lb)

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15-30

Compression, checking


Special tools and equipment

VAG1381 or VAG1763 compression tester
3122B spark plug removal tool

Test condition
Minimum engine oil temperature: 30 C (86
F)

Test procedure

- Remove engine covers.

- Switch ignition off and remove harness
connectors to ignition coils.

- Unbolt ignition coils (arrows).
- Remove all harness connectors to fuel injectors.
- Using 3122B spark plug removal tool, remove all spark plugs.
- Open throttle to Wide Open Throttle (WOT) position.
- Using VAG1381 or VAG1763 compression tester, test engine
compression.
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15-31

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

Compression pressure

Engine code
New
Wear limit

AEB 10.0-13.0 bar
(145-188.5 psi) 7.0 bar
(101.5 psi)
Permissible difference between all cylinders: 3
bar (43 psi)

- Install spark plugs and ignition coils.

- Check DTC memory.

Repair Manual, 1.8 Liter 5V Turbo Fuel
Injection & Ignition, Repair Group 01
Note:
Diagnostic Trouble Codes (DTCs) are stored
when harness connectors are disconnected.
After testing, check DTC memory and erase.
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