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

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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15-10

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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15-15

Installing
Installation is the reverse of removal, noting the
following:

Note:
Replace gaskets and O-rings.

- Adjust Accelerator Pedal (AP) cable.

Repair Manual, Fuel Supply System, Repair
Group 20


- Top up 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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15-16

- 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
torques
Intake manifold to cylinder
head 10 Nm (7 ft lb)
Intake manifold brace to intake
manifold 20 Nm (15 ft lb)
Intake manifold to bracket 20 Nm (15 ft lb)
Fuel supply rail to intake
manifold 10 Nm (7 ft lb)
Coolant line to coolant flange 10 Nm (7 ft lb)
Coolant line to intake manifold 10 Nm (7 ft lb)
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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.
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15-19

Tightening torques

Component
Tightening
torques
Cylinder head cover to cylinder
head 10 Nm (7 ft lb)
Ignition coils to cylinder head
cover 10 Nm (7 ft lb)
Crankcase ventilation line to
cylinder head cover 10 Nm (7 ft lb)
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15-20

Cylinder head, removing


Engine installed
Lock carrier in service position Page 13
-1

Note:

Secure all hose connections with original
equipment clamps parts catalog.

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.
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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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