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Checking compression > < Removing cylinder head - engine codes ANB, APU, ARK, ATW

A4 Mk1

Installing cylinder head
Installing cylinder head
  Caution
Avoid damage to sealing surfaces.
t  Carefully remove sealant residue from cylinder head and cylinder block.
t  Ensure that no long scores or scratches are made on the surfaces.
Avoid damage to cylinder block.
No oil or coolant must be allowed to remain in the blind holes for the cylinder head bolts in the cylinder block.
Risk of leaks at cylinder head gasket.
t  Carefully remove any sealant residue from the cylinder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces.
t  Carefully remove any remaining emery and abrasive material.
t  Do not remove new cylinder head gasket from packaging until it is ready to be fitted.
t  Handle the cylinder head gasket very carefully to prevent damage to the silicone coating or the indented area of the gasket.
Avoid damage to open valves.
When installing an exchange cylinder head, the plastic protectors fitted to protect the open valves should not be removed until the cylinder head is ready to be fitted.
  Note
t  Renew the bolts tightened with specified tightening angle.
t  Renew self-locking nuts as well as seals, gaskets and O-rings.
t  When installing an exchange cylinder head, the contact surfaces between the hydraulic compensation elements, roller rocker fingers and cams must be oiled before installing the cylinder head.
t  Hose connections and air pipes and hoses must be free of oil and grease before assembly.
t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue.
t  After fitting a new cylinder head or cylinder head gasket, change the engine oil and the coolant in the entire cooling system.
   
–  Before installing cylinder head, set camshaft to “TDC”-top arrow-.
–  Make sure that crankshaft is in “TDC” position -bottom arrow-; turn crankshaft via toothed belt sprocket bolt if necessary.
  A15-0024
–  Slacken bolts -1- and -2- on support for turbocharger (about 2 full turns each) so that components remain free of stress when installing cylinder head.
  A15-0172
–  Place cylinder head gasket in position.
l  Note position of centralising pins in cylinder block -arrows-.
l  Check installation position of cylinder head gasket; the Part No. should be legible from inlet side.
–  Fit cylinder head.
–  Insert and hand-tighten cylinder head bolts.
  A15-0135
–  Tighten cylinder head bolts → Fig..
  Note
Cylinder head bolts do not have to be torqued down again later after repair work.
Remaining installation steps are carried out in reverse sequence; note the following:
–  Secure turbocharger with new gasket to exhaust manifold and secure bracket to cylinder block → Chapter.
–  Install cylinder head cover → Chapter.
–  Install toothed belt (adjust valve timing): vehicles up to 05.1999 → Anchor, vehicles from 06.1999 onwards → Anchor.
–  Install poly V-belt and tensioner for poly V-belt → Chapter.
–  Install intake manifold → Chapter.
–  Install coolant hoses and air hoses with screw-type clips → Fig..
–  Connect coolant hose with plug-in connector → Fig..
Vehicles with throttle cable:
–  Adjust throttle cable → Rep. Gr.20.
All vehicles (continued):
–  Observe notes on procedure for connecting the battery → Rep. Gr.27.
–  Change engine oil → Booklet802.
–  Fill cooling system with fresh coolant → Anchor.
Tightening torques → Chapter, → Chapter
  A15-0023

Checking compression > < Removing cylinder head - engine codes ANB, APU, ARK, ATW