Audi Workshop Service and Repair Manuals

Notes:

• ◆ Always renew cylinder head bolts when assembling.
• ◆ When performing repairs, renew seals, gaskets, self-locking nuts and bolts which have a specified tightening angle.
• ◆ 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.
• ◆ Only remove new cylinder head gasket from packaging when ready for installation.
• ◆ Handle gasket extremely carefully. Damaging the silicone layer or the indented area will lead to leaks.
• ◆ No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.

• ‒ → Before positioning cylinder head, set crankshaft and camshaft to TDC of No. 1 cylinder.

• ‒ → Place cylinder head gasket in position.
• ‒ Note position of centralizing pins in cylinder block -arrows-.
• ‒ Check installation position of cylinder head gasket, marking: spare parts no. must be legible from inlet side.
• ‒ Place cylinder head in position.
• ‒ Insert cylinder head bolts and tighten by hand.

• ‒ → Tighten cylinder head bolts in two stages in sequence shown as follows:
• ‒ Stage 1: 60 Nm
• ‒ Stage 2: Torque a further
      180 °(1/2 turn) with a rigid wrench.
  It is permissible to torque by
      2 x 90 °.

Note:

It is not necessary to re-tighten cylinder head bolts after repairs have been performed.

• ‒ Install cylinder head cover.

• ‒ Install toothed belt (adjust valve timing).

Note:

Follow all instructions for removing and installing toothed belt .

• ‒ Install ribbed belt and ribbed belt tensioning element.
• ‒ Install top coolant pipe.
• ‒ Install intake manifold.
• ‒ Adjust throttle cable
• ‒ Fill cooling system with fresh coolant => Page 19-7.
• ‒ After connecting battery, enter anti-theft code for radio

=> Radio operating instructions

• ‒ Close windows fully using electric window switches.
• ‒ Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
• ‒ Set clock to correct time.

• ‒ Perform adaption of throttle valve control part:

=> Motronic injection and ignition system (4-cylinder); Repair Group 24; Checking throttle valve control part -J338; Performing basic setting of throttle valve control part -J338

=> Motronic injection and ignition system (4-cylinder)07.96 ä;Repair group 24; Testing throttle valve control part; Adapting throttle valve control part to engine control unit

Tightening torques