Audi 80/90/Coupe

Since 1986-1991 of release

Repair and car operation



Audi 80/90/Coupe
+ 1.2. Car identification
- 2. Engines, carburettors
   2.1.2. Removal and engine installation (5-cylinder models)
   2.1.3. Dismantling and assemblage of engines
   2.1.4. A head of the block of cylinders, the mechanism timing
   + 2.2. An engine electric equipment
   + 2.3. Carburettors
3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. An exhaust system
+ 7. Ignition system
+ 8. Transmission
+ 9. Suspension brackets, wheels
+ 10. Brake system
+ 11. A steering
+ 12. A body, salon
+ 13. A central air
+ 14. An electric equipment





2.1.4. A head of the block of cylinders, the mechanism timing
THE GENERAL DATA

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

1. A stopper маслозаливной mouths
2. A cover of a head of the block
3. An intensifying lining
4. Consolidation of a cover of a head of the block
5. A gear wheel of a drive of a cam-shaft
Watch correctness of installation of a gear wheel at belt replacement
6. The top cover of a belt of a drive of a cam-shaft
7. Gear ременьпривода a cam-shaft
8. 45 Н.м.
9. A roller натяжителя
10. A back cover of a belt of a drive of a cam-shaft
11. 25 Н.м.
12. A lining of a head of the block
The label "OBEN" should be turned towards a block head
13. Consolidation
Necessarily replace
14. A cam-shaft cover
15. A bolt of a head of the block

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

Head deformation is checked by calibre 1030 and probeом

Maximum deviation from a plane of 0,1 mm


The prevention

Before check carrying out, the block head should be pure, the material of linings 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 correct position 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 a following order (the engine cold):
   – Tighten bolts in the established sequence with the moment 40 Н.м.;
   – Tighten bolts in the established sequence with the moment 60 Н.м.;
   – One movement tighten on 180 ;
It is supposed to carry out доворот in two steps on 90 ;
   – отворачивание bolts it is made upside-down.

The 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 threads are damaged only is supposed.



Cam-shaft / valves (4-cylinder models)

 

1. 20 Н.м.
2. Covers of bearings рарпредвала watch symmetry of landing of covers
3. A hydraulic pusher
Before installation check up axial люфт a cam-shaft
Grease a contact surface
After removal, store a contact surface downwards
4. The bottom plate
Removal / installation is carried out
The 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. A cam-shaft epiploon

9. A head of the block of cylinders
10. The directing plug
11. A maslosemnyj 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 шпонка
Check up landing
16. 80 Н.м.
17. A cam-shaft
Check axial люфта is carried out in conformity
Cam-shaft identification is carried out in conformity
The radial backlash of basic bearings is checked by plastic calibre
Limiting backlash 0, 1 mm
Limiting development of 0,01 mm

Check axial люфта

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

Display adaptation VW 387 establish according to drawing

Axial люфт it is measured by cam-shaft displacement in an 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 wrong landing displacement 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 коленвал in ВМТ the first cylinder
4) ослабьте a tension also remove a gear belt
5) remove from a cam-shaft segment шпонку
6) remove covers of 1 and 3rd bearings
7) remove a cover of 2 and 5th bearings, turning on nuts in stages in a cross order

Installation

The prevention

At installation of a cam-shaft cams having on the first cylinder should be turned upwards.


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

Hydraulic pushers – check
The prevention

The removed pusher put on a pure place contact (with a cam-shaft) a surface downwards.


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

At the first start-up of the engine the rumble of low frequency from outside the mechanism timing is supposed.
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 has not disappeared, arrive as follows:
Uncover block heads;
Turn коленвал for a pulley bolt clockwise so that cam-shaft cams have been directed upwards;
Wooden stick slightly displace a pusher;
If the pusher departs more than on 0,1 mm replace it


The prevention

After pusher replacement, engine start is supposed 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 коленвал in ВМТ the first cylinder
3) ослабьте a tension also remove a gear belt
4) remove a cam-shaft gear wheel
5) remove from a cam-shaft segment шпонку
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) запрессуйте an epiploon by means of the adaptation 10–203 before exhibiting of an obverse surface of an epiploon заподлицо with the case

The sizes of valves

The sizes of valves in mm

The inlet valve
The final valve
Diameter and
40,0
33,0
Diameter b
7,97
7,95
Length with
91,0
90,8

The prevention

Polishing of valves on the machine tool is not supposed.


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 size of repolishing (facet removal) saddles b turns out

Calculations of the maximum permissible size of repolishing of a saddle b

Insert the valve and strongly press to a saddle

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

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

The minimum size

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

Saddle of the inlet valve – repolishing

And = 39,2 mm

b = the maximum permissible size of repolishing

Z = a plane of a head of the block of cylinders

30 = a corner of an aligning facet

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

Saddle of the final valve – repolishing

And = 32,4 mm

b = the maximum permissible size of repolishing

With = 2,4 mm are approximately equal

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

30 = a corner of an aligning facet

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

Grinding in of valves


The prevention

Machine grinding in is not supposed.


On a saddle put притирочную paste, insert the valve into a saddle and turn in a direction forward-back (it is specified by arrows), having clamped the valve in оправку

The prevention

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


Directing plugs check

Check of directing plugs is carried out first of all.
PERFORMANCE ORDER
1) remove the rests of a deposit solvent
2) backlash measurement is carried out by means of display adaptation VW 387
3) insert into directing plug the new valve
4) the end face of a core of the valve should coincide with plug edge
The prevention

Inlet and final valves should be established in corresponding plugs.


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

Directing plugs replacement


The prevention

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


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

The prevention

If on directing plugs there is a fillet which is provided by a design выпрессовывать them it is necessary from outside combustion chambers.


2) on new plugs put greasing and запрессуйте them in a cold head of the block from outside a cam-shaft; запрессовывайте before full landing of plugs

The 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 smazochno-cooling эмульсией and develop plugs by means of development 10-215
4) прошлифуйте saddles of valves

Maslosemnye 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 position of hairpins
5) screw in a carving aperture of a spark plug a head of a tester 1106 or an equivalent adapter, submit pressure not less than 6 атм
6) remove springs stripper VW 541/1

The prevention

If crackers badly give in to removal to weaken their landing it is possible for lungs постукиванием on the lever оправки adaptations.


7) by means of the adaptation 3047 remove маслосъемные caps
8) put on the plastic plug And a valve core
9) grease маслосъемный a cap In, insert it in оправку 10-204 and cautiously dress a cap on directing plug

The prevention

It is not supposed to establish маслосъемные caps without a plastic protector, otherwise the cap will be damaged and the expense of oil the engine 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.


The prevention

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 Н.м.
2. An intensifying lining
3. A spring washer
4. A back cover of a belt of a drive of a cam-shaft
5. A gear wheel
At belt replacement, watch for
Correctness of position of a gear wheel
6. 80 Н.м.
7. The top cover of a belt of a drive of a cam-shaft
8. 10 Н.м.
9. A gear belt of a drive of a cam-shaft
10. The remote plug
11. A lining of a head of the block
Before removal remember head position
Establish on pins in the block of cylinders
12. The block of cylinders
13. A head of the block of cylinders
14. A bolt of a head of the block
Observe an assembly order
15. Consolidation of a head of the block
Is subject to replacement
16. A cover гоповки the block of cylinders.

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

Installation of a head of the block of cylinders


The prevention

Installation коленвала in ВМТ is not supposed.


PERFORMANCE ORDER
1) screw directing hairpins of the adaptation 3070 in apertures of 9 and 10th bolts of fastening of a head of the block
2) establish a lining of a head of the block on aligning hairpins (are specified by arrows)
3) attach a block head to the block of cylinders
4) turn the others 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 apertures of 9 and 10th bolts of fastening of a head of the block; wrap 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 вворачивания and inhalings

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 40 Н.м.

2 – an inhaling with the moment 60 Н.м.

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


The 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 supposed, or the carvings of inserts of candles first some threads are damaged only.


Valve cam-shaft / (5-cylinder engines)
 
1. Covers of bearings of a cam-shaft
2. 20 Н.м.
3. A cam-shaft
Check axial люфта is carried out
In conformity
Cam-shaft identification
It is carried out in conformity
The radial backlash of basic bearings is checked by plastic calibre
Limiting backlash of 0,1 mm
4. A cam-shaft epiploon
Grease working and external edges
5. Crackers
6. External and internal springs
Removal / installation by the adaptation 2037
7. A maslosemnyj cap
8. The bottom plate
Removal / installation by the adaptation 3047
9. The directing plug
10. A block head
The size maintained at repolishing and = of 132,75 mm
11. Valves
12. A head of the block of cylinders
13. The directing plug
14. The 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 up axial люфт a cam-shaft
To repair and mutual substitution are not subject
Before replacement check up axial люфт a cam-shaft

Cam-shaft, check axial люфта


Measure at the removed pushers and 1 cover 1 and 4th bearings

Limiting axial люфт 0,15 mm


Cam-shaft identification

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

Covers of bearings of a cam-shaft – installation

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

Check up correctness of position of covers of bearings on symmetry of their installation

The 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


The prevention

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


Calculation of the maximum permissible size 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 size of repolishing of a saddle 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 size of repolishing (facet removal) saddles b turns out

The minimum size

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

Saddle of the inlet valve – repolishing

And = 39,2 mm

b = the maximum permissible size of repolishing

With = about 2,0 mm

Z = a plane of a head of the block of cylinders

30 = a corner of an aligning facet

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

Saddle of the final valve – repolishing

And = 32,4 mm

b = the maximum permissible size of repolishing

With = about 2,0 mm

Z = a plane of a head of the block of cylinders

30 = a corner of an aligning facet

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

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

Pusher check

The removed pusher put on a pure place contact (with a cam-shaft) a surface downwards

Always replace a pusher in gathering

The pusher is not subject to repair or adjustment

1) at the first start-up of the engine the raised noise from outside pushers is supposed
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 has not disappeared, arrive as follows:
4а) uncover block heads
4б) turn коленвал for a pulley bolt clockwise so that cams of a cam-shaft of the corresponding cylinder have been directed upwards
4в) a wooden stick slightly displace a pusher;
If the pusher departs more than on 0,1 mm replace it

The prevention

After replacement of a pusher engine start is supposed not earlier than through 30 mines as impact of valves with pistons is possible. For correct adjustment it is necessary to provide full обезгаживание 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 коленвал in ВМТ 1st cylinder
3) ослабьте a belt tension, remove a belt
4) remove a conducted gear wheel of a cam-shaft
5) get from a cam-shaft segment шпонку
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 накаткой 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) запрессуйте an epiploon by means of the adaptation 10-203 until then while the forward plane of an epiploon will not be established заподлицо with a case surface;
At запрессовке use a special bolt 10-203/1 with шестигранной a head

The prevention

It is not supposed запрессовка an epiploon against the stop. Otherwise the return oil channel will be blocked.



Cam-shaft

Arrangement of valves / a cam-shaft in gathering (Compartment model)

1. Covers of bearings of a cam-shaft
2. 15 Н.м.
3. An epiploon
4. A chain of a drive of a cam-shaft
5. An external spring of the valve
Removal / installation is carried out by the adaptation 2037 and / or the adaptation 2036 together with VW541/1 and emphasis VW 541/5
6. An 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 пором VW 541/5
7. The bottom plate of a spring
Removal / installation is carried out by the adaptation 3047А
8. A maslosemnyj cap
9. The directing plug
10. A head of the block of cylinders
11. Inlet and final valves
Grind in only manually
12. Cam-shaft cams
13. Pushers
14. Crackers
15. The top plate of a spring

The 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 supposed, or the carvings of inserts of candles first some threads 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 коленвал in ВМТ 1st cylinder
5) ослабьте 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 segment шпонку
8) remove covers of 1 and 3rd bearings;
Turn away a nut of fastening of covers of 2 and 4th bearings in a cross order on a diagonal

Installation

At installation of a cam-shaft cams of 1st cylinder should be turned upwards

At installation of covers of bearings watch symmetry of their arrangement

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

Directing plugs – deterioration check

At deterioration check inlet and final valves establish in corresponding directing plugs as diameters of cores of these valves differ a little

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

Directing plugs – replacement

Head of the block of cylinders, saddles of valves which do not suppose the further polishing, or the head of the block of the cylinders, exposed to polishing till the limiting size, is not subject to the further repair.

PERFORMANCE ORDER
1) выпрессуйте the worn out directing plugs from outside 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 outside combustion chambers
3) on new plugs put greasing and запрессуйте the adaptation 10-206 in a cold head of the block from outside a cam-shaft
4) запрессуйте against the stop in a fillet
5) develop plugs manually by means of development 10-215
6) development carry out with smazochno-cooling эмульсией
7) прошлифуйте saddles of valves

The prevention

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


Maslosemnye caps

Removal (without removal of a head of the block)


The 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 in a spark plug aperture, submit constant pressure not less than 6 атм
6) remove springs stripper VW 541/1
7) if crackers badly give in to removal to weaken their landing it is possible easy постукиванием a hammer on the adaptation lever

Installation

Arrangement of components


PERFORMANCE ORDER
1) put on the plastic plug And a valve core
2) grease маслосъемный a cap In and cautiously dress a cap on directing plug together with a plastic protector

The 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. A stopper маслозаливной mouths
2. A mechanism cover timing
The moment of an inhaling of bolts of fastening 10 Н.м.
3. A bolt of a head of the block
4. 65 Н.м.
5. A conducted gear wheel of a cam-shaft
At installation of a gear belt watch position ориентационной labels

6. A head of the block of cylinders
7. A lining of a head of cylinders
8. A cover lining газораспределительного the mechanism
9. A lining
10. A soaking up collector
The moment of an inhaling of bolts of fastening
20 Н.м.

Head of the block of cylinders – deformation check


The prevention

Before performance of check the block head should be cleared, the material of linings should be removed.


Head deformation is checked by calibre 1030 and probeом

Maximum deviation from a plane of 0,1 mm

Head of the block of cylinders – polishing

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

The minimum size of 118,1 mm

Head of the block of cylinders – installation


The prevention

Before installation of a head of the block of cylinders be convinced that коленвал it is established in ВМТ, and cam-shaft labels are combined.


PERFORMANCE ORDER
1) establish a lining of a head of the block on pins so that the party with marks "OBEN" (or with detail number) has been 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 40 Н.м.
Tighten bolts with the moment 60 Н.м.
One movement tighten on 180 (it is supposed to carry out доворот in two steps on 90 )
Bolts upside-down turn away

The prevention

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