Audi 80/90/Coupe

since 1986-1991 release

Repair and operation of the car



Audi 80/90/Coupe
+ 1.2. Identification of the car
- 2. Engines, carburetors
   2.1.2. Removal and installation of the engine (5-cylinder models)
   2.1.3. Dismantling and assembly of engines
   2.1.4. Head of the block of cylinders, gas distribution mechanism
   + 2.2. Engine electric equipment
   + 2.3. Carburetors
3. Lubrication system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Exhaust system
+ 7. System of ignition
+ 8. Transmission
+ 9. Suspension brackets, wheels
+ 10. Brake system
+ 11. Steering
+ 12. Body, salon
+ 13. Air conditioning system
+ 14. Electric equipment






2.1.4. Head of the block of cylinders, gas distribution mechanism

GENERAL INFORMATION

The block of cylinders in collecting (4-cylinder models)

1. Stopper of a maslozalivny mouth
2. Block head cover
3. Intensifying laying
4. Consolidation of a cover of a head of the block
5. Cam-shaft drive gear wheel
you watch correctness of installation of a gear wheel when replacing a belt
6. Top cover of a belt of the drive of a cam-shaft
7. Gear remenprivoda of a cam-shaft
8. 45 N. of m.
9. Roller of a natyazhitel
10. Back cover of a belt of the drive of a cam-shaft
11. 25 N. of m.
12. Laying of a head of the block
the tag of "OBEN" has to be turned towards a block head
13. Consolidation
surely replace
14. Cam-shaft cover
15. Block head bolt

The head of cylinders can be removed without dismantle of the engine from the car.

At installation of the repaired head grease contact surfaces of cams of a cam-shaft and pushers.

Head of the block of cylinders – deformation check

deformation of a head is checked by caliber 1030 and the probe

tolerance from the plane of 0,1 mm


Prevention

Before conducting check, the head of the block has to be pure, material of laying has to be removed.


Installation of a head of the block of cylinders

Order of an inhaling of bolts

 


PERFORMANCE ORDER
1) place a block head on the block of cylinders
2) install a block head on the block of cylinders
3) find the correct provision of a head
4) screw all bolts of a head of the block
5) tighten bolts by hand
6) tighten bolts in three steps in the following order (the engine cold):
   – tighten bolts in the established sequence with m 40 N.' moment;
   – tighten bolts in the established sequence with m 60 N.' moment;
   – one movement tighten on 180 °;
it is allowed to carry out доворот in two steps on 90 °;
   – the otvorachivaniye of bolts is made upside-down.

Prevention

Additional tightening of a head of the block both at routine maintenance, and after repair is not required.

Installation of a head of the block with cracks in seats of saddles of valves, and also inserts of spark plugs without reduction of term of operation of a head is allowed provided that width of cracks does not exceed 0,5 mm or if only the first several strings of a carving of inserts are damaged.



Cam-shafts / valves (4-cylinder models)

 

1. 20 N. of m.
2. Covers of bearings of a rarpredval you watch symmetry of landing of covers
3. Hydraulic pusher
before installation check an axial side play of a cam-shaft
grease a contact surface
after removal, you store a contact surface down
4. Lower plate
removal / installation is carried out
adaptation 3047
5. Consolidation
is subject to obligatory replacement
6. Valves
перешлифовкв are not subject
7. The size maintained when regrinding and = 132,6 mm
8. Cam-shaft epiploon

9. Head of the block of cylinders
10. The directing plug
11. Oil scraper cap
12. External and internal springs removal / installation is carried out by adaptation 2037
13. The plate of a spring of the valve differs on outer diameter
14. Crackers
15. Segment spline
check landing
16. 80 N. of m.
17. Cam-shaft
check of an axial side play is carried out in compliance
identification of a cam-shaft is carried out in compliance
the radial gap of basic bearings is checked by plastic caliber
limit gap 0, 1 mm
limit development of 0,01 mm

Check of an axial side play

measure at the removed pushers and the established covers of the 1st and 5th bearings

install indicator VW 387 adaptation according to the drawing

the axial side play is measured by cam-shaft shift in the direction of an arrow

limit side play of 0,15 mm


Identification of a cam-shaft

basic diameter of a cam and = 34,0 mm


Engine code
Arrow I
Arrow II
3A
G
026

Covers of bearings of a cam-shaft

Before installation of a cam-shaft pay attention to landing of covers of bearings. At the wrong landing the shift of covers is observed. Correctly establish covers.

Correct installation
 

Cam-shaft

 

Removal

PERFORMANCE ORDER
1) remove the top cover of a gear belt
2) uncover a block head
3) turn the crankshaft in VMT of the first cylinder
4) weaken a tension and take off a gear belt
5) remove a segment spline from a cam-shaft
6) uncover the 1 and 3 bearings
7) uncover the 2 and 5 bearings, turning off nuts in stages in a cross order

Installation

Prevention

At installation of a cam-shaft the cams falling on the first cylinder have to be turned up.


PERFORMANCE ORDER
1) fix covers of the 2 and 5 bearings; moment of an inhaling of 20 N. of m.
2) fix covers of the 1 and 3 bearings; moment of an inhaling of 20 N. of m.
3) fix a cam-shaft gear wheel; moment of an inhaling of 80 N. of m.

Hydraulic pushers – check
Prevention

Put the removed pusher on the pure place contact (with a cam-shaft) a surface down.


Always replace a pusher in collecting (the pusher is not subject to repair or adjustment).

At the first launch of the engine the rumble of low frequency from the gas distribution mechanism is allowed.
PERFORMANCE ORDER
1) warm up the engine before the first operation of the electric fan
2) bring engine speed to 2500 rpm, keep the engine in such mode within 2 min.

3) if noise of pushers did not disappear, then arrive as follows:
uncover a block head;
turn the crankshaft for a pulley bolt clockwise so that cams of a cam-shaft were directed up;
wooden stick slightly displace a pusher;
if the pusher departs more than on 0,1 mm, then replace it


Prevention

After replacement of a pusher, start of the engine is allowed not earlier than in 30 minutes as impact of valves with pistons is possible.



Cam-shaft epiploon

Removal


PERFORMANCE ORDER
1) remove the top cover of a gear belt
2) turn the crankshaft in VMT of the first cylinder
3) weaken a tension and take off a gear belt
4) remove a cam-shaft gear wheel
5) remove a segment spline from a cam-shaft
6) screw against the stop a bolt of fastening of a gear wheel of a cam-shaft (together with a washer)
7) turn out an internal cartridge of a stripper of 2085 from external on two turns (about 3 mm) and record the screw
8) grease a carving part of a stripper of an epiploon
9) establish a stripper and with the maximum effort insert into an epiploon
10) release the screw and rotate an internal cartridge of a stripper concerning a cam-shaft to a full exit of an epiploon

11) clamp a stripper in a vice and get an epiploon flat-nose pliers


Installation

PERFORMANCE ORDER
1) slightly grease working and external edges of an epiploon
2) press an epiploon by means of adaptation 10-203 before exposure of an epiploon to a front surface aflush with the case

Sizes of valves

The sizes of valves in mm

Inlet valve
Final valve
Diameter and
40,0
33,0
Diameter of b
7,97
7,95
Length with
91,0
90,8

Prevention

Grinding of valves on the machine is not allowed.


If necessary, carry out grinding in manually.

Saddles of valves – regrinding

The minimum size for the inlet valve of 33,8 mm

The minimum size for the final valve of 34,1 mm

"And" to subtract the minimum size from the measured distance

The maximum permissible amount of regrinding (removal of a facet) of b saddle turns out

Calculations of the maximum permissible amount of regrinding of a saddle of b

insert the valve and strongly press to a saddle

measure distance and between an end face of a core of the valve and the plane of a head of the block

calculate the maximum permissible amount of regrinding of a saddle of b, knowing the size and

Minimum size

if the measured distance and is less than the minimum size, then a hydraulic pusher will not work and the head of the block of cylinders should be replaced

Saddle of the inlet valve – regrinding

and = 39,2 mm

b = maximum permissible amount of regrinding

Z = plane of a head of the block of cylinders

30 ° = a corner of the aligning facet

45 ° = valve saddle facet corner

Saddle of the final valve – regrinding

and = 32,4 mm

b = maximum permissible amount of regrinding

with = 2,4 mm are approximately equal

Z = the plane of a head of the block of cylinders (from the lower party)

30 ° = a corner of the aligning facet

45 ° = valve saddle facet corner

Grinding in of valves


Prevention

Machine grinding in is not allowed.


apply pritirochny paste on a saddle, insert the valve into a saddle and turn in the direction back and forth (it is specified by shooters), having clamped the valve in a mandrel

Prevention

After grinding in of the valve remove the remains of abrasive material.


The directing plugs check

Check of the directing plugs is carried out first of all.
PERFORMANCE ORDER
1) remove the deposit remains solvent
2) measurement of a gap is carried out by means of indicator VW 387 adaptation
3) insert the new valve into the directing plug
4) the end face of a core of the valve has to coincide with edge of the plug
Prevention

Inlet and final valves have to be installed in the corresponding plugs.


5) shake the valve, having rested against it an indicator leg
6) wear of guides corresponds to the indication of the indicator
1. Indication of the indicator
2. Inlet valves
3. Final valves
1,0 mm
1,3 mm

The directing plugs replacement


Prevention

The head of the block of cylinders, a saddle of valves in which does not allow further grinding, or the head of the block of cylinders which was exposed to grinding to the extreme size, is not subject to further repair.


PERFORMANCE ORDER
1) to a vypressuyta worn-out guides of the plug from a cam-shaft by means of adaptation 10-206

Prevention

If on the directing plugs there is a fillet which is provided by a design, then it is necessary to press off them from the combustion chamber.


2) apply lubricant on new plugs and press them in a cold head of the block from a cam-shaft; press before full landing of plugs

Prevention

When the fillet of the directing plug adjoins to a block head, do not use the efforts more than 1 ton as the fillet can be cut off.


3) grease plugs with the lubricant cooling emulsion and deploy plugs by means of development 10-215
4) to a proshlifuyta of a saddle of valves

Oil scraper caps replacement (without removal of a head of the block)
PERFORMANCE ORDER
1) remove a cam-shaft and pushers
2) turn out spark plugs
3) install the piston of the corresponding cylinder in the lower dead point
4) establish an emphasis 2036 and adjust the provision of hairpins
5) screw in a carving opening of a spark plug a head of a tester 1106 or an equivalent adapter, give pressure not less than 6 atm
6) remove springs VW 541/1 stripper

Prevention

If crackers badly give in to removal, then it is possible to weaken their landing easy percussion on adaptation mandrel lever.


7) by means of adaptation 3047-A remove oil scraper caps
8) put on the plastic plug A a valve core
9) grease an oil scraper cap In, insert it into a mandrel 10-204 and carefully dress a cap on the directing plug

Prevention

It is not allowed to establish oil scraper caps without plastic protector, otherwise the cap will be the oil consumption the engine is damaged and will increase.


The head of the block of cylinders can be removed without dismantle of the engine from the car.

At installation of the repaired head of the block grease cams of a cam-shaft and hydraulic pushers.


Prevention

The wrong installation of the conducted gear wheel of a cam-shaft leads to early opening of valves and to a possibility of impact of valves with pistons.


Head of the block of cylinders (5-cylinder models)

1. 10 N. of m.
2. Intensifying laying
3. Spring washer
4. Back cover of a belt of the drive of a cam-shaft
5. Gear wheel
when replacing a belt, you watch for
correctness of provision of a gear wheel
6. 80 N. of m.
7. Top cover of a belt of the drive of a cam-shaft
8. 10 N. of m.
9. Gear belt of the drive of a cam-shaft
10. Remote plug
11. Laying of a head of the block
before removal remember the provision of a head
install on pins in the block of cylinders
12. Block of cylinders
13. Head of the block of cylinders
14. Block head bolt
observe an assembly order
15. Consolidation of a head of the block
is subject to replacement
16. Cover of a gopovka of the block of cylinders.

Head of the block of cylinders – deformation check
the maximum deviation from the plane of 0,1 mm

Installation of a head of the block of cylinders


Prevention

Installation of the crankshaft in VMT is not allowed.


PERFORMANCE ORDER
1) screw the directing adaptation 3070 hairpins in openings of the 9 and 10 bolts of fastening of a head of the block
2) establish laying of a head of the block on the aligning hairpins (are specified by shooters)
3) attach a block head to the block of cylinders
4) wrap other 10 bolts of a head of the block, tighten them by hand
5) the screw-driver of adaptation 3070 turn out the directing hairpins from openings of the 9 and 10 bolts of fastening of a head of the block; wrap the 9th and 10th bolts of fastening of a head of the block, tighten them by hand

Bolts of fastening of a head of the block an order of a vvorachivaniye and an inhaling

Order of an inhaling of bolts


tighten bolts according to numbering in the drawing, turn off upside-down

Tighten bolts in three steps on the cold engine:

1 – an inhaling with m 40 N.' moment.

2 – an inhaling with m 60 N.' moment.

3 – an inhaling – tighten on 1/2 turns (180 °) one movement (it is allowed доворот in two steps on 90 °)


Prevention

Installation of a head of the block with cracks in seats of saddles of valves, or inserts of saddles, and also inserts of spark plugs without reduction of term of operation of a head is allowed provided that width of cracks does not exceed 0,5 mm, or only the first several strings of a carving of inserts of candles are damaged.


Cam-shaft / valve (5-cylinder engines)
 
1. Covers of bearings of a cam-shaft
2. 20 N. of m.
3. Cam-shaft
check of an axial side play is carried out
in compliance
identification of a cam-shaft
it is carried out in compliance
the radial gap of basic bearings is checked by plastic caliber
limit gap of 0,1 mm
4. Cam-shaft epiploon
grease working and external edges
5. Crackers
6. External and internal springs
removal / installation by adaptation 2037
7. Oil scraper cap
8. Lower plate
removal / installation by adaptation 3047
9. The directing plug
10. Block head
the size maintained when regrinding and = 132,75 mm
11. Valves
12. Head of the block of cylinders
13. The directing plug
14. Top plate of a valve spring
differs in the flat wide external surface turned towards a cam-shaft
15. Hydraulic pushers
before installation of new pushers check an axial side play of a cam-shaft
are not subject to repair and mutual substitution
before replacement check an axial side play of a cam-shaft

Cam-shaft, check of an axial side play


measure at the removed pushers and the 1 and 4 bearings installed a cover

limit axial side play of 0,15 mm


Identification of a cam-shaft

the identification tag "034L" is put between cams of the 1st cylinder

Covers of bearings of a cam-shaft – installation

before installation of a cam-shaft grease the surfaces of bearings and a support

check correctness of provision of covers of bearings on symmetry of their installation

Valve sizes

 

Inlet
Final
a
40,0 mm
33,0 mm
b
7,97 mm
7,95 mm
with
91,0 mm
90,8 mm
d
45 °
45 °


Prevention

Grinding of valves is not allowed. Only saddles are ground.


Calculation of the maximum permissible amount of regrinding of a saddle

PERFORMANCE ORDER
1) insert the valve and strongly press to a saddle
2) measure distance and between an end face of a core of the valve and the top plane of a head of the block
3) calculate the maximum permissible amount of regrinding of a saddle of b, knowing the size and

Saddles of valves – regrinding

The minimum size for the inlet valve of 33,8 mm

The minimum size for the final valve of 34,1 mm

"And" to subtract the minimum size from the measured distance

The maximum permissible amount of regrinding (removal of a facet) of b saddle turns out

Minimum size

If the measured distance and is less than the minimum size, then a hydraulic pusher will not work and the head of the block of cylinders should be replaced.

Saddle of the inlet valve – regrinding

and = 39,2 mm

b = maximum permissible amount of regrinding

with = about 2,0 mm

Z = plane of a head of the block of cylinders

30 ° = a corner of the aligning facet

45 ° = valve saddle facet corner

Saddle of the final valve – regrinding

and = 32,4 mm

b = maximum permissible amount of regrinding

with = about 2,0 mm

Z = plane of a head of the block of cylinders

30 ° = a corner of the aligning facet

45 ° = valve saddle facet corner

Inserts of final valves have smaller diameter. When grinding saddles do not damage the top edge.

Check of a pusher

put the removed pusher on the pure place contact (with a cam-shaft) a surface down

always replace a pusher assembled

the pusher is not subject to repair or adjustment

1) at the first launch of the engine the increased noise from pushers is allowed
2) warm up the engine before the first operation of the electric fan
3) bring engine speed to 2500 rpm, keep the engine in such mode within 2 min.
4) if noise of pushers did not disappear, then arrive as follows:
4a) uncover a block head
4b) turn the crankshaft for a pulley bolt clockwise so that cams of a cam-shaft of the corresponding cylinder were directed up
4v) a wooden stick slightly displace a pusher;
if the pusher departs more than on 0,1 mm, then replace it

Prevention

After replacement of a pusher start of the engine is allowed not earlier than in 30 min. as impact of valves with pistons is possible. For the correct adjustment it is necessary to provide full outgassing of a pusher.


Cam-shaft epiploon

Removal

PERFORMANCE ORDER
1) remove the top cover of a belt of the drive of a cam-shaft
2) install the crankshaft in VMT of the 1st cylinder
3) weaken a belt tension, take off a belt
4) remove the conducted cam-shaft gear wheel
5) get a segment spline from a cam-shaft
6) wrap against the stop a cam-shaft bolt together with a washer
7) turn out an internal cartridge of a stripper of 2085 from external on two turns (about 3 mm) and record the screw
8) grease a carving part of a stripper of an epiploon
9) establish a stripper and with effort insert into an epiploon
10) release the screw with a nakatka and rotate an internal cartridge of a stripper concerning a cam-shaft to a full exit of an epiploon
11) clamp a stripper in a vice and get an epiploon flat-nose pliers

Installation

PERFORMANCE ORDER
1) slightly grease sponges and an external part of an epiploon
2) press an epiploon by means of adaptation 10-203 until the forward plane of an epiploon is not established aflush with the surface of the case;
at a press fitting use a special bolt 10-203/1 with a six-sided head

Prevention

The epiploon press fitting against the stop is not allowed. Otherwise the reverse oil channel will be blocked.



Cam-shaft

Arrangement valves / cam-shaft in collecting (Coupet's model)

1. Covers of bearings of a cam-shaft
2. 15 N. of m.
3. Epiploon
4. Cam-shaft drive chain
5. External spring of the valve
removal / installation is carried out by adaptation 2037 and / or adaptation 2036 together with VW541/1 and an emphasis of VW 541/5
6. Internal spring of the valve
removal / installation is carried out by adaptation 2037 and / or adaptation 2036 together with VW 541/1 and at the VW 541/5 ferry
7. Lower plate of a spring
removal / installation is carried out by adaptation 3047A
8. Oil scraper cap
9. The directing plug
10. Head of the block of cylinders
11. Inlet and final valves
grind in only manually
12. Cam-shaft cams
13. Pushers
14. Crackers
15. Top plate of a spring

Prevention

Installation of a head of the block with cracks in seats of saddles of valves or inserts of saddles, and also inserts of spark plugs without reduction of term of operation of a head is allowed provided that width of cracks does not exceed 0,5 mm, or only the first several strings of a carving of inserts of candles are damaged.


Removal

PERFORMANCE ORDER
1) remove the top cover of a belt of the drive of a cam-shaft
2) remove the top part of the soaking-up branch pipe
3) uncover a head of the block of cylinders
4) install the crankshaft in VMT of the 1st cylinder
5) weaken a tension of a gear belt, take off a belt
6) remove the conducted cam-shaft gear wheel
7) get a segment spline from a cam-shaft
8) uncover the 1 and 3 bearings;
turn off nuts of fastening of covers of the 2 and 4 bearings in a cross order on diagonal

Installation

at installation of a cam-shaft cams of the 1st cylinder have to be turned up

at installation of covers of bearings you watch symmetry of their arrangement

PERFORMANCE ORDER
1) check correctness of an arrangement of covers preliminary statement them into place
2) tighten nuts of fastening of covers of the 2 and 4 bearings in a cross order on diagonal; moment of an inhaling of 20 N. of m.
3) establish covers of the 1 and 3 bearings; moment of an inhaling of 20 N. of m.
4) establish the conducted gear wheel of a cam-shaft and tighten with the moment 80 N. of m.

The directing plugs – wear check

when checking wear install inlet and final valves in the corresponding guides of the plug as diameters of cores of these valves differ a little

PERFORMANCE ORDER
1) remove the deposit remains
2) install indicator VW 387 adaptation
3) insert the new valve into the directing plug
4) the end face of a core of the valve has to coincide with edge of the plug
5) shake the valve, having rested against it an indicator leg
6) wear of the directing plugs corresponds to the indication of the indicator
1. Limit indication of the indicator
2. Inlet valves
3. Final valves

The directing plugs – replacement

The head of the block of cylinders, saddles of valves which do not allow further grinding or the head of the block of cylinders which was exposed to grinding to the extreme size, is not subject to further repair.

PERFORMANCE ORDER
1) to a vypressuyta worn-out guides of the plug from a cam-shaft by means of adaptation 10-206
2) if on the directing plugs there is a fillet, then it is necessary to press off them from the combustion chamber
3) apply lubricant on new plugs and press adaptation 10-206 in a cold head of the block from a cam-shaft
4) press against the stop in a fillet
5) deploy plugs manually by means of development 10-215
6) carry out development with the lubricant cooling emulsion
7) to a proshlifuyta of a saddle of valves

Prevention

After landing of a guide of the plug to a fillet do not use the efforts more than 1 ton, otherwise breakage of a fillet is possible.


Oil scraper caps

Removal (without removal of a head of the block)


Prevention

After landing of a guide of the plug to a fillet do not use the efforts more than 1 ton, otherwise breakage of a fillet of the directing plug is possible.


Arrangement of tools


PERFORMANCE ORDER
1) turn out spark plugs
2) remove a cam-shaft and pushers
3) install the piston of the corresponding cylinder in N.M.T.
4) establish an emphasis 2036 and adjust on height of hairpins
5) insert a hose 1106 or VW653/3 into a spark plug opening, give constant pressure not less than 6 atm
6) remove springs VW 541/1 stripper
7) if crackers badly give in to removal, then it is possible to weaken their landing easy percussion by the hammer on adaptation lever

Installation

Arrangement of components


PERFORMANCE ORDER
1) put on the plastic plug A a valve core
2) grease an oil scraper cap In and carefully dress a cap on the directing plug together with a plastic protector

Prevention

Not to damage a cap, it is necessary to establish them only with a plastic protector.

After installation of new pushers, the engine should be started not earlier than in 30 minutes, otherwise damage of the piston is possible.



Head of the block of cylinders (Coupet's model)


1. Stopper of a maslozalivny mouth
2. Gas distribution mechanism cover
moment of an inhaling of bolts of fastening of 10 N. of m.
3. Block head bolt
4. 65 N. of m.
5. The conducted cam-shaft gear wheel
at installation of a gear belt you monitor the provision of an orientation tag

6. Head of the block of cylinders
7. Laying of a head of cylinders
8. Laying of a cover of the gas-distributing mechanism
9. Laying
10. The soaking-up collector
moment of an inhaling of bolts of fastening
20 N of m.

Head of the block of cylinders – deformation check


Prevention

Before check performance the head of the block should be cleared, material of laying has to be removed.


deformation of a head is checked by caliber 1030 and the probe

tolerance from the plane of 0,1 mm

Head of the block of cylinders – grinding

measure distance between the plane of bolts of fastening of a head and the lower plane

the minimum size is 118,1 mm

Head of the block of cylinders – installation


Prevention

Before installation of a head of the block of cylinders be convinced that the crankshaft is installed in VMT, and tags of a cam-shaft are combined.


PERFORMANCE ORDER
1) establish laying of a head of the block on pins so that the party with marking of "OBEN" (or with number of a detail) was turned towards a head
2) establish a block head, wrap block head bolts, tighten bolts by hand
3) tighten bolts in the established sequence in three steps, observing the following order (the engine cold):
tighten bolts with m 40 N.' moment.
tighten bolts with m 60 N.' moment.
one movement tighten on 180 ° (it is allowed to carry out доворот in two steps on 90 °)
bolts upside-down turn away

Prevention

Additional tightening of bolts of a head of the block both at routine maintenance, and after repair, is not required.