Audi 80/90/Coupe

since 1986-1991 of release

Repair and car operation



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


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2.1.4. Head of the block of cylinders, gazoraspredeleniye mechanism

GENERAL INFORMATION

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

1. Stopper of a maslozalivny mouth
2. Cover of a head of the block
3. Intensifying laying
4. Consolidation of a cover of a head of the block
5. Gear wheel of a drive of a cam-shaft
watch correctness of installation of a gear wheel at belt replacement
6. Top cover of a belt of a drive of a cam-shaft
7. Gear ременьпривода cam-shaft
8. 45 N of m.
9. Roller of a natyazhitel
10. Back cover of a belt of a drive of a cam-shaft
11. 25 N of m.
12. Laying of a head of the block
the label of "OBEN" should be turned towards a block head
13. Consolidation
surely replace
14. Cam-shaft cover
15. Bolt of a head of the block

The head of cylinders can be removed without engine dismantle 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 calibre 1030 and shchupy

tolerance from the plane of 0,1 mm


Prevention

Before carrying out check, the head of the block should be pure, the material of laying should 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) establish 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 the moment of 40 N of m;
   – tighten bolts in the established sequence with the moment of 60 N of m;
   – 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 it 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 provided that the width of cracks does not exceed 0,5 mm or if the carvings of inserts first some strings are damaged only is allowed.



Cam-shafts / valves (4-cylinder models)

 

1. 20 N of m.
2. Covers of bearings рарпредвала watch symmetry of landing of covers
3. Hydraulic pusher
before installation check axial люфт a cam-shaft
grease a contact surface
after removal, store a contact surface down
4. Bottom 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 at repolishing and = of 132,6 mm
8. Cam-shaft epiploon

9. Head of the block of cylinders
10. The directing plug
11. Maslosyemny cap
12. External and internal springs removal / installation is carried out by the adaptation 2037
13. The plate of a spring of the valve differs on external diameter
14. Crackers
15. Segment shponka
check landing
16. 80 N of m.
17. Cam-shaft
check axial люфта 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 calibre
limiting gap 0, 1 mm
limiting development of 0,01 mm

Check axial люфта

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

the display VW 387 adaptation establish according to drawing

axial люфт it is measured by cam-shaft shift in the arrow direction

limiting люфт 0,15 mm


Cam-shaft identification

base diameter of a cam and = 34,0 mm


Engine code
Arrow I
Arrow II
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 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 block heads
3) turn the crankshaft in VMT of the first cylinder
4) weaken a tension and remove a gear belt
5) remove from a cam-shaft a segment shponka
6) remove covers 1 and the 3rd bearings
7) remove covers 2 and the 5th bearings, turning on nuts in stages in a cross order

Installation

Prevention

At cam-shaft installation cams falling on the first cylinder should be turned up.


PERFORMANCE ORDER
1) fix covers 2 and the 5th bearings; moment of an inhaling of 20 N of m.
2) fix covers 1 and the 3rd 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

The removed pusher put on a 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 start-up of the engine the rumble of low frequency is allowed from the gazoraspredeleniye mechanism.
PERFORMANCE ORDER
1) warm up the engine before the first operation of the electrofan
2) finish number of turns of the engine to 2500 rpm, keep the engine in such mode during 2 mines

3) if noise of pushers did not disappear, arrive as follows:
uncover block heads;
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, replace it


Prevention

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



Cam-shaft epiploon

Cнятие


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 remove a gear belt
4) remove a cam-shaft gear wheel
5) remove from a cam-shaft a segment shponka
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 2085 of external on two turns (about 3 mm) and fix 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 the adaptation 10-203 before exposure of an obverse surface of an epiploon 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

Polishing of valves on the machine is not allowed.


If necessary, carry out grinding in manually.

Saddles of valves – repolishing

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

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

From the measured distance "and" to subtract the minimum size

The maximum permissible amount of repolishing (facet removal) b saddles turns out

Calculations of the maximum permissible amount of repolishing 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 repolishing of a saddle of b, knowing the size and

Minimum size

if the measured distance and is less than the minimum size, a hydraulic pusher will not work and it is necessary to replace a head of the block of cylinders

Saddle of the inlet valve – repolishing

and = 39,2 mm

b= maximum permissible amount of repolishing

Z= plane of a head of the block of cylinders

30 ° = a corner of an aligning facet

45 ° = corner of a facet of a saddle of the valve

Saddle of the final valve – repolishing

and = 32,4 mm

b= maximum permissible amount of repolishing

with = 2,4 mm are approximately equal

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

30 ° = a corner of an aligning facet

45 ° = corner of a facet of a saddle of the valve

Grinding in of valves


Prevention

Machine grinding in is not allowed.


on a saddle put pritirochny paste, insert the valve into a saddle and turn in the direction forward-back (it is specified by shooters), having clamped the valve in an opravka

Prevention

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


Directing plugs check

Check of 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 the display VW 387 adaptation
3) insert into directing plug the new valve
4) the end face of a core of the valve should coincide with edge of the plug
Prevention

Inlet and final valves should be established in the corresponding plugs.


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

Directing plugs replacement


Prevention

The head of the block of cylinders a saddle of valves in which does not allow further polishing, or a head of the block of the cylinders, being exposed to polishing till the limiting size, is not subject to further repair.


PERFORMANCE ORDER
1) выпрессуйте worn-out directing plugs from a cam-shaft by means of the adaptation 10-206

Prevention

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


2) on new plugs put greasing and press them in a cold head of the block from a cam-shaft; press before complete landing of plugs

Prevention

When the fillet of the directing plug will adjoin to a block head, do not put effort more than 1 ton as the fillet can be cut off.


3) grease plugs with a lubricant cooling emulsion and develop plugs by means of development 10-215
4) прошлифуйте saddles of valves

Maslosjemnye 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) establish the piston of the corresponding cylinder in the bottom 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, submit pressure not less than 6 atm
6) remove springs VW 541/1 stripper

Prevention

If crackers badly give in to removal, to weaken their landing it is possible an easy postukivaniye on the lever of an opravka of the adaptation.


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

Prevention

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


The head of the block of cylinders can be removed without engine dismantle 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 a conducted gear wheel of a cam-shaft leads to early opening of valves and to 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 a drive of a cam-shaft
5. Gear wheel
at belt replacement, watch for
correctness of provision of a gear wheel
6. 80 N of m.
7. Top cover of a belt of a drive of a cam-shaft
8. 10 N of m.
9. Gear belt of a drive of a cam-shaft
10. Remote plug
11. Laying of a head of the block
before removal remember the provision of a head
establish on pins in the block of cylinders
12. Block of cylinders
13. Head of the block of cylinders
14. Bolt of a head of the block
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

Crankshaft installation in VMT is not allowed.


PERFORMANCE ORDER
1) screw directing hairpins of the adaptation 3070 in openings 9 and the 10th bolts of fastening of a head of the block
2) establish laying of a head of the block on 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) a screw-driver of the adaptation 3070 turn out directing hairpins from openings 9 and the 10th 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 a vvorachivaniye and inhaling order

Order of an inhaling of bolts


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

Tighten bolts in three steps on the cold engine:

1–an inhaling with the moment of 40 N of m.

2–an inhaling with the moment of 60 N of m.

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 provided that the width of cracks does not exceed 0,5 mm is allowed, or the carvings of inserts of candles first some strings are damaged only.


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

Cam-shaft, check axial люфта


measure at the removed pushers and established a cover 1 and the 4th bearings

limiting axial люфт 0,15 mm


Cam-shaft identification

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

Covers of bearings of a cam-shaft – installation

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

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

Sizes of the valve

 

The inlet
The 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

Polishing of valves is not allowed. Saddles are ground only.


Calculation of the maximum permissible amount of repolishing 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 repolishing of a saddle of b, knowing the size and

Saddles of valves – repolishing

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

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

From the measured distance "and" to subtract the minimum size

The maximum permissible amount of repolishing (facet removal) b saddles turns out

Minimum size

If the measured distance and is less than the minimum size, a hydraulic pusher will not work and it is necessary to replace a head of the block of cylinders.

Saddle of the inlet valve – repolishing

and = 39,2 mm

b= maximum permissible amount of repolishing

with = about 2,0 mm

Z= plane of a head of the block of cylinders

30 ° = a corner of an aligning facet

45 ° = corner of a facet of a saddle of the valve

Saddle of the final valve – repolishing

and = 32,4 mm

b= maximum permissible amount of repolishing

with = about 2,0 mm

Z= plane of a head of the block of cylinders

30 ° = a corner of an aligning facet

45 ° = corner of a facet of a saddle of the valve

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

Pusher check

the removed pusher put on a 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 start-up of the engine the increased noise is allowed from pushers
2) warm up the engine before the first operation of the electrofan
3) finish number of turns of the engine to 2500 rpm, keep the engine in such mode during 2 mines
4) if noise of pushers did not disappear, arrive as follows:
4а) uncover block heads
4б) turn the crankshaft for a pulley bolt clockwise so that cams of a cam-shaft of the corresponding cylinder were directed up
4в) a wooden stick slightly displace a pusher;
if the pusher departs more than on 0,1 mm, replace it

Prevention

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


Cam-shaft epiploon

Removal

PERFORMANCE ORDER
1) remove the top cover of a belt of a drive of a cam-shaft
2) establish the crankshaft in VMT of the 1st cylinder
3) weaken a belt tension, remove a belt
4) remove a conducted gear wheel of a cam-shaft
5) get from a cam-shaft a segment shponka
6) wrap against the stop a cam-shaft bolt together with a washer
7) turn out an internal cartridge of a stripper 2085 of external on two turns (about 3 mm) and fix 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 the adaptation 10-203 until then while the forward plane of an epiploon will not be established aflush with a case surface;
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 return oil channel will be blocked.



Cam-shaft

Arrangement valves / cam-shaft in collecting (Compartment model)

1. Covers of bearings of a cam-shaft
2. 15 N of m.
3. Epiploon
4. Chain of a drive of a cam-shaft
5. External spring of the valve
removal / installation is carried out by the adaptation 2037 and / or the adaptation 2036 together with VW541/1 and VW 541/5 emphasis
6. Internal spring of the valve
removal / installation is carried out by the adaptation 2037 and / or the adaptation 2036 together with VW 541/1 and at the VW 541/5 ferry
7. Bottom plate of a spring
removal / installation is carried out by the adaptation 3047А
8. Maslosjemny 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 provided that the width of cracks does not exceed 0,5 mm is allowed, or the carvings of inserts of candles first some strings are damaged only.


Removal

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

Installation

at cam-shaft installation cams of the 1st cylinder should be turned up

at installation of covers of bearings 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 2 and the 4th bearings in a cross order on a diagonal; moment of an inhaling of 20 N of m.
3) establish covers 1 and the 3rd bearings; moment of an inhaling of 20 N of m.
4) establish a conducted gear wheel of a cam-shaft and tighten with the moment of 80 N of m.

Directing plugs – wear check

at wear check inlet and final valves establish in the corresponding directing plugs as diameters of cores of these valves differ a little

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

Directing plugs – replacement

The head of the block of cylinders, saddles of valves which do not allow further polishing, or a head of the block of the cylinders, being exposed to polishing till the limiting size, is not subject to further repair.

PERFORMANCE ORDER
1) выпрессуйте worn-out directing plugs from a cam-shaft by means of the adaptation 10-206
2) if on directing plugs there is a fillet, выпрессовывать them it is necessary from the combustion chamber
3) on new plugs put greasing and press the adaptation 10-206 in a cold head of the block from a cam-shaft
4) press against the stop in a fillet
5) develop plugs manually by means of development 10-215
6) development carry out with a lubricant cooling emulsion
7) прошлифуйте saddles of valves

Prevention

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


Maslosjemnye caps

Removal (without removal of a head of the block)


Prevention

After landing of the directing plug to a fillet do not put effort more 1тонны, breakage of a fillet of the directing plug otherwise is possible.


Arrangement of tools


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

Installation

Arrangement of components


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

Prevention

Not to damage a cap, to establish them follows only with a plastic protector.

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



Head of the block of cylinders (Compartment model)


1. Stopper of a maslozalivny mouth
2. Cover of the mechanism of a gazoraspredeleniye
moment of an inhaling of bolts of fastening of 10 N of m.
3. Bolt of a head of the block
4. 65 N of m.
5. A conducted gear wheel of a cam-shaft
at installation of a gear belt watch the provision of an oriyentatsionny label

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. A 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, the material of laying should be removed.


deformation of a head is checked by calibre 1030 and shchupy

tolerance from the plane of 0,1 mm

Head of the block of cylinders – polishing

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

minimum size of 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 established in VMT, and labels of a cam-shaft are combined.


PERFORMANCE ORDER
1) establish laying of a head of the block on pins so that the party with "OBEN" marking (or with detail number) was turned towards a head
2) establish a block head, wrap bolts of a head of the block, tighten bolts by hand
3) tighten bolts in the established sequence in three steps, observing the following order (the engine cold):
tighten bolts with the moment of 40 N of m.
tighten bolts with the moment of 60 N of m.
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, it is not required.