Audi A3

since 1997 of release

Repair and car operation



Audi A3
+ Maintenance instruction
+ Current leaving and service
- Engine
   Compression check in engine cylinders
   Engine check by means of the vacuum gage
   Removal and installation of the bottom cover of an impellent compartment
   Removal and engine/RKPP installation
   - Four-cylinder petrol engines 1.6, 1.8 of l
      Installation of the piston of the first cylinder in VMT
      Removal, installation and tension of a gear belt
      Removal and installation of a head of cylinders
      Removal and installation of a ridge maple belt
   + Diesel engines
   + Major maintenance
   + greasing System
+ Systems of cooling, heating
+ the Power supply system and production of the fulfilled gases
+ engine Electric equipment
+ Manual box of gear shifting
+ Automatic transmission and models with a full drive
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Elektroskhema









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Removal and installation of a head of cylinders

GENERAL INFORMATION

Head of cylinders (engine of 1.6 l)

1–bolt, 15 N of m
2–bolt, 20 N of m
3–back cover of a gear belt
4–head of cylinders
5–bolts of fastening of a head of cylinders
Surely replace with the new
6–oil divider
7–sealing laying of a cover of a head of cylinders. In the presence of damages replace with the new. Before installation into place grease with AUDI hermetic – “D2” transitions a cover bearings/head of cylinders
8–intensifying level
9–cover of a head of cylinders
10-bolt, 10 N of m
11-the top part of a soaking-up pipe
12-nut, 10 N of m
13-stopper of a maslozalivny mouth
14-sealing ring
15-case of the ventilating device
6–sealing laying
In the presence of damages replace with the new.
17-nut, 10 N of m
18-holder
19-consolidation
20-the lower part of a soaking-up pipe
21-bolt, 20 N of m
22-consolidation of the inlet pipeline
Surely replace with the new.
23-stopper, 15 N of m
24-sealing ring
Surely replace with the new.
25-flange
26-bolt, 10 N of m
29-eye
30-laying of a head of cylinders
Surely replace with the new. Watch correctness of installation. After installation of a head of cylinders it is necessary to replace system with new cooling liquid.

To define damage of laying of a head of cylinders it is possible on the following signs:

– Engine capacity loss
– Loss of cooling liquid. Existence of white clouds in the fulfilled gases on the heated-up engine.
– Oil loss.
– Cooling liquid in impellent oil, level of oil does not decrease, and raises. Gray color of impellent oil, vials on the level index, liquid oil.
– Impellent oil in cooling liquid
– Strong foaming in cooling liquid.
– Lack of a compression in two next cylinders.


ATTENTION

Here removal of a head of cylinders of the petrol engine of 1.8 l is described. Data concerning engines of 1.6 l are separately given also. As the detailed description of all operations is not obviously possible, before removal of a head of cylinders it is necessary to check once again, whether all pipelines and other accessions are disconnected from a head of cylinders and to it.
The head of cylinders is necessary for removing only on the cold engine (room temperature). The final collector is not disconnected, the inlet pipeline acts in film.


REMOVAL

PERFORMANCE ORDER
1. The engine should have temperature not above hand temperature if it is necessary, wait, while the engine will be cooled.
2. Disconnect a negative cable (–) the storage battery at the switched-off ignition.

ATTENTION

Thereof information from electronic blocks of memory, as, for example, a radio receiver code is erased. Without a code the radio receiver can be included only by the manufacturer or HUNDRED AUDIS. Therefore familiarize with remarks in subsection Input of a code of a radio receiver.


3. Merge liquid from cooling system, thus address to subsection Replacement of cooling liquid.
4. Remove spark plugs.
5. Remove the air filter, thus address to the subsection Removal and installation of the case of the air filter.

ATTENTION

The fuel system is under pressure! Before opening of shlangovy connections it is necessary to close them a thick rag. Then, carefully turning on, to remove pressure. Use goggles, danger of a travmirovaniye of eyes!


6. Disconnect pipelines of giving and fuel return from the fuel distributive highway. Thus compress fixing keys on the coupling. For simplification of the subsequent assembly mark pipelines.
7. Close opened the pipeline polyethylene and rubber rings to exclude hit of pollution in them.
8. Rasstykuyte I will corrode injectors of fuel and take aside.
9. Disconnect all electric wires from a head of cylinders to a body. Mark connection by a tape to restore connection at assembly.
10. Unscrew bolts of fastening and disconnect the top part of the inlet pipeline from the holder. Remark: On an illustration the engine of 125 h.p. is shown.
11. Unscrew bolts of fastening and disconnect the inlet pipeline from a head of cylinders.
Engine of 1.6 l
12. Rasstykuyte I will corrode – 1–at the valve of switching of the inlet pipeline. Disconnect a vacuum hose–2–from a pressure regulator.
13. Remove stoppers at the left and on the right at the inlet pipeline (the shooter on an illustration).
14. Unscrew bolts of fastening and disconnect the inlet pipeline from a head of cylinders.
15. Disconnect all hoses of cooling liquid from a head of cylinders. For this purpose open collars and shift them back. If necessary mark hoses and the corresponding branch pipes not to mix them at assembly.
16. Unscrew bolts of fastening and disconnect a reception pipe with the catalytic converter from a final collector, thus address to the subsection Removal and installation of system of release.
17. Disconnect directing pipe of air from a collar–4–and unscrew bolts of fastening–2–and–3–at the holder. Unscrew bolts of fastening–1–and–5–thermoprotective leaves of system of pressurization behind at a head of cylinders.
18. Remove maple a belt, thus address to the subsection Removal and installation of a ridge maple belt.
19. Engines of 1.8 l: Disconnect the tension device of a maple belt, thus address to the subsection Removal and installation of a ridge maple belt.
20. Remove the top protective cover of a gear belt. Establish a cranked shaft in VMT of the piston of the first cylinder, thus address to subsection Installation of the piston of the first cylinder in VMT.
21. Weaken a gear belt by means of a tension roller. Remove a gear belt only above from a camshaft wheel, completely do not remove it, thus address to the subsection Removal, installation and a tension of a gear belt.
22. Mark the provision of a pulley of a cranked shaft. For this purpose put markings by paint on a pulley of a cranked shaft and the block of cylinders. Then turn a pulley of a kolonchaty shaft on 1/4 turns (90 °) forward or back, to exclude finding of any piston in VMT. Before installation of a gear belt it is necessary to establish again a cranked shaft in VMT of the piston of the first cylinder.
23. Unscrew bolts of fastening of a cover of a head of cylinders and remove together with laying.
Engine of 1.8 l

ATTENTION

Bolts of fastening of a head of cylinders should turn away in sequence of numbering with 1 on 10.


Engines 1.6
24. Turn out bolts of fastening of a head of cylinders. Thus for the engine of 1.8 l the long face key of 8 mm (for example is necessary, for HAZET 990 2749), for the engine 1.6 a key under an internal polyhedron (for example, to HAZET 990 Slg-12).
25 whether. Check all pipelines and the hoses conducting to a head of cylinders are disconnected.
26. Remove a head of cylinders and establish it on two wooden whetstones.
27. Remove a sealing head of cylinders.

INSTALLATION


ATTENTION

The new head of cylinders has plastic linings for protection of open valves. Linings act in film only before installation. Address with laying extremely carefully. Damage leads further to tightness loss.


PERFORMANCE ORDER
1. Before installation a head and the block of cylinders carefully clear the corresponding shaber of the hermetic remains. Watch that dirt did not get to openings of the block of cylinders. Close openings rags.
ATTENTION

Watch that on surfaces after a shabreniye there were no risks of big length. If the emery paper, granularity it is applied should not exceed 100.


2. Check, whether contain openings for bolts of fastening of a head of cylinders oil, if necessary remove oil. For this purpose enter into openings a pure rag and collect with its help oil.
ATTENTION

If oil remains in openings, at an inhaling of bolts of fastening the block of cylinders can be damaged.


3. Check in various places of a head of cylinders by means of a steel ruler and щупа plane deformation. The tolerance from planeness should not exceed 0.1 mm.
4. Check of a surface of interface of a head on deformation by means of a steel ruler and щупа.
5. After carrying out polishing of a head, the size "a" should be not less specified in Specifications.

ATTENTION

If the interfaced planes of a head of cylinders are ground, the admissible minimum height of a head should not be values less presented in Specifications.


6. The heads of cylinders having risks between saddles of valves or rings of saddles and the first rounds of a carving under spark plugs can be applied and under repair further without decrease in their service life if the width рисок does not exceed 0.5 mm.
7. Bolts of fastening and sealing laying of a head of cylinders surely replace with the new.
8. Pins for a centering of a head of cylinders. Engine of 1.8 l
9. For a centering of a head of cylinders screw in external openings of bolts of fastening of a head of cylinders directing fingers of AUDI-3070/9 the tool for a vvorachivaniye 3070 (engines of 1.6 l: Directing fingers of AUDI-3450).
10. There are also directing fingers of HAZET, No. 2570. If directing fingers available are not present, it is possible to apply 2 old bolts of fastening with the cut-off heads. For the subsequent reversing on bolts saw through grooves.
11. Engines of 1.8 l: For a centering of a head of cylinders there are 2 pins. If necessary insert pins.
12. Put new sealing laying of a head of cylinders so that marking (spare part No.) was from a branch pipe of inlet valves. Laying without hermetic put so that openings remained open.
ATTENTION

Address with laying carefully. Even small damages can lead to a leakage. New laying is taken out from packing only directly ahead of installation.


13. Put a head of cylinders by means of the assistant into place, thus watch directing pins in the block of cylinders.
14. Establish 8 bolts of fastening of a head of cylinders with washers and tighten them by hand. Bolts are established the surely new.
15. Engines of 1.6 l: Turn out bolts of fastening by a screw-driver, insert 2 remained bolts and tighten them by hand.
ATTENTION

The inhaling of bolts of fastening of a head of cylinders should be carried out with special care. Before an inhaling of bolts check a dinamometrichesky key on accuracy. Bolts are tightened at the cold engine.


16. Bolts of fastening are tightened for some receptions. For each reception bolts are tightened in sequence with 1 on 10 efforts given in Specifications.

ATTENTION

At an inhaling of bolts of fastening of a head of cylinders the angle of rotation is estimated as follows. Put the key handle along the engine and turn so that the handle rose across the engine (1/4 turns = 90 °).

The tightening of bolts of fastening of a head of cylinders on the warm engine within carrying out maintenance or repair is not allowed.

After installation of a head of cylinders oil contact surfaces of pushers and cams.


17. Establish distributive and cranked shaft in position VMT of the piston of the first cylinder, thus address to подазделу Installation of the piston of the first cylinder in VMT.
18. Before installation of consolidation of a cover of a head of cylinders grease with D2 hermetic transitions from covers of bearings to a head of cylinders, and also on the opposite side. Put laying of a head of the cylinders, the damaged laying replace.
19. Put a cover of a head of cylinders and fix it cross-wise the moment of 10 N • m.
20. Put on a gear belt a wheel of a camshaft and pull, thus address to the subsection Removal, installation and a tension of a gear belt.
21. Fix a reception pipe with the catalytic converter on a final collector, thus address to the subsection Removal and installation of system of release.
22. Engines from turbokompressory 1.8 l (150 h.p.): Fix behind a pipe of supply of air and the heat-shielding screen of system of pressurization.
23. Fix bolts cross-wise the inlet pipeline with new laying by the moment of 10 N of m on a head of cylinders.
24. Fix the inlet pipeline on the holder the moment of 25 N of m.
25. Fix the pipeline of giving and fuel return on a distributive pipe.
26. Connect electric wires, for example, at the sensor of the Hall and at injectors according to the markings put at removal, and fix them.
27. Engines of 1.8 l: Fix a natyazhitel of a maple belt the moment of 25 N of m.
28. Establish maple a belt, thus address to the subsection Removal and installation of a ridge maple belt.
29. Establish spark plugs.
30. Check, whether all wires, fuel hoses, hoses of system of cooling and vacuum hoses according to the put markings are attached.
31. Check in the engine oil level, if necessary fill system with oil.

ATTENTION

If the head of cylinders acted in film owing to laying damage, it is recommended to make oil replacement, including oil in the filter as in impellent oil there is a cooling liquid.


32. Mix new cooling liquid and water and fill in in system, thus address to subsection Replacement of cooling liquid.
33. Establish the air filter, thus address to the subsection Removal and installation of the case of the air filter.
34. Attach a negative cable (–) to a battery battery room.

ATTENTION

Make active automatic equipment of safety of window regulators, enter a radio receiver code, establish hours, thus address to subsection Input of a code of a radio receiver.


35. Pass on the car. After that check level of oil and cooling liquid. Check on tightness all shlangovy connections.