engine oil AUDI A4 1996 B5 / 1.G AEB ATW Engines Cylinder Head Remove And Install Workshop Manual

15-17

Cylinder head cover, removing and
installing


Removing

- Remove engine covers.

- Unbolt crankcase ventilation line from heatshield and cylinder head
cover and disconnect line from front hose (arrows).
- Swing crankcase ventilation line to side.
- Remove 2 retaining clamps for upper toothed belt cover.
- Disconnect harness connectors at ignition coils -1- and unbolt Ground
(GND) connection -2-.
- Unbolt ignition coils.

- Remove cylinder head cover nuts (arrows) and remove cylinder head
cover.
Pa
ge 17 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2

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
.
Pa
ge 22 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2

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.
Pa
ge 25 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2

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)

Pa
ge 31 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2

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.
Pa
ge 32 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2

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.
Pa
ge 34 of 35 C
ylinder head, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.15.2