coolant AUDI A4 1999 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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15-2


Part I - Cylinder head components

1 -
Cylinder head gasket
Replacing Removing cylinder head,
Page 15
-20

Installation position: Part No. to cylinder
head After replacing, fill with fresh coolant
2 -
Cylinder head Removing Page 15
-20
Check for distortion Fig. 1
, Page
15
-7
Reworking dimension Fig. 2
, Page
15
-7
Installing Page 15
-28
.
After replacing, fill with fresh coolant
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15-4


10 -
Cylinder head cover gasket
Replace if damaged or leakingBefore installing gasket apply "AMV 174
004 01" to sealing points Fig. 3
and
Fig. 4
, Page 15
-8
11 -
Gasket
Always replace
12 -
Combi valve for secondary air inlet With screw connection
13 -
10 Nm
14 -
Coolant flange With coolant temperature sensor
15 -
10 Nm
16 -
O-ring Always replace
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15-5


Part II - Intake manifold components

1 -
Gasket
Note installation positionAlways replace
2 -
10 Nm
3 -
10 Nm
4 -
O-ring For injectorAlways replace
5 -
Fuel rail With injectors
6 -
Top coolant line
7 -
10 Nm
8 -
10 Nm
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15-6


9 -
O-ring
For top coolant lineAlways replace
10 -
10 Nm
11 -
Intake manifold Removing and installing Page 15
-9
12 -
20 Nm
13 -
Support
For intake manifold
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15-9

Intake manifold, removing and installing


Removing

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

- Disconnect Ground strap at battery with ignition
switched off.

- Remove engine cover -arrows-.
- Drain coolant Page 19
-4 .

- Disconnect coolant hoses -1- and -3-.
- Unbolt coolant expansion tank -2- (-arrows-).
- Disconnect electrical wiring to coolant level display switch -F66- on
bottom of expansion tank.
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ylinder head, removin
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15-12

- Disconnect coolant hoses from upper coolant
line.

- Move electrical wiring at top of coolant line
aside.

- Unbolt upper coolant line from intake manifold and coolant flange -
arrows- at back of cylinder head.

- Remove intake line support -arrows-.
- Disconnect hose -1- to ACF valve on intake line.
- Pull out oil dipstick.
- Remove bracket of guide line for oil dipstick.
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15-13

- Remove suction hose from flange and
remove.

Note:
Plug intake ports on cylinder head with clean
cloths.

Installing
Installation is carried out in the reverse order of
removal; note the following:

Note:

All cable ties which are released or cut open
when removing must be located in the same
position when installing.
Hose connections and hoses of charge air
system must be free of oil and grease before
assembling.
Replace seals and gaskets.

- Top up coolant Page 19
-7 .

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