2000 AUDI A4 engine

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.
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15-26


- Loosen bolts -1- and -2- at turbocharger bracket two turns to reduce
likelihood of any tension while installing cylinder head.

Note: - Install cylinder head gasket.
Pay close attention to pilot pins (arrows) in engine block.Pay attention to installation position marking for cylinder head gasket:
Part number must be visible from intake side.
- Install cylinder head.
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15-27

- Insert cylinder head bolts and hand tighten.

Note:
It is not necessary to re-tighten the bolts.
Note:
Follow all procedures for removing and installing toothed belt Page 13
-
29
. - Tighten cylinder head bolts in sequential order, in two stages:

Step 1 = 60 Nm (44 ft lb)
Step 2 = additional 1/2 turn using rigid wrench (180 is equivalent
to two 90 turns)
- Using new gasket, bolt turbocharger to exhaust manifold and bolt
bracket to engine block Page 21
-24
.
- Install cylinder head cover Page 15
-18
.
- Install toothed belt (adjust valve timing) Page 13
-32
.
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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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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.
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11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.GE02.15.2