1996 AUDI A4 coolant

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.
Pa
ge 1 of 42 C
ylinder head, removin
g and installin
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11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
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yp
e=re
pair&id=AUDI.B5.GE06.15.1

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
Pa
ge 3 of 42 C
ylinder head, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.15.1

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
Pa
ge 5 of 42 C
ylinder head, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.15.1

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
Pa
ge 6 of 42 C
ylinder head, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.15.1

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
Pa
ge 7 of 42 C
ylinder head, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.15.1

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.
Pa
ge 10 of 42 C
ylinder head, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
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e=re
pair&id=AUDI.B5.GE06.15.1

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.
Pa
ge 13 of 42 C
ylinder head, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.15.1

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.
Pa
ge 14 of 42 C
ylinder head, removin
g and installin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE06.15.1