lock AUDI A4 1997 B5 / 1.G AWM Engine Cylinder Head Remove And Install Workshop Manual

15-1


Cylinder head, removing and
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.
The hose connectors and hoses of charge air
system must be free of oil and grease before
assembling.
When installing an exchange cylinder head with
the camshafts installed, the contact surfaces
between bucket tappet and cam running
surface must be oiled after installation of the
cylinder head.
The plastic protectors fitted to protect the open
valves must only be removed immediately
before installing the cylinder head.
When installing a new cylinder head or cylinder
head gasket, drain off all the old coolant and re-
fill with new coolant.
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15-14

- Actuate all power window switches again for at
least one second in the "close" direction to
activate 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
Injection & Ignition, Engine Code(s): AWM , Repair Group 24


Tightening torques

Component

Nm
Intake manifold to cylinder head 10
Support for intake
manifold to intake
manifold 20
to bracket 20
Fuel manifold to intake manifold 10
Coolant line to coolant flange 10
Coolant line on intake line 10
Hose clamps for coolant hoses
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15-21

Procedure

Engine in vehicle
Lock carrier must be in service position
Page 13
-1 .

Note:
All cable ties which are released or cut open
when removing must be located in the same
position when installing.

- Observe or obtain radio anti-theft code on
vehicles with coded radio.

- Disconnect Ground strap at battery with ignition
switched off.

- Drain coolant Page 19
-4 .

- Remove intake line Page 15
-9 .

- Remove ribbed belt and tensioner for ribbed belt
Page 13
-18
.

- Remove air filter cover -arrow-.
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15-28

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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15-29


- 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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15-31

- 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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ylinder head, removin
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15-32

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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