Audi 80/Avant (B4)

Since 1991-1995 of release

Repair and car operation



Audi 80/Avant
+ The description
- Engines
   Basic elements
   Greasing system
   Ventilation картера
   Visual check of the engine
   Обкатка the new engine
   Engine service life
   Nominal and maximum frequency of rotation
   Restriction of frequency of rotation
   Measurement of pressure of compression
   The list of malfunctions
   Проворачивание the engine
   Hydraulic pushers
   Works on gear belt ГРМ
   The list of malfunctions
   Removal and installation of a head of the block of cylinders
   Removal and engine installation
+ System of release of the fulfilled gases
+ Cooling system
+ Fuel tank and the fuel pump
+ The air filter and воздухозаборные channels
+ Injection system
+ Coupling
+ Transmission and transmission
+ Suspension bracket and steering
+ Brake system
+ Antiblocking system of brakes
+ Wheels and tyres
+ Kuzovnaja electrosystem
+ Ignition system
+ Illumination
+ Signalling devices
+ Devices and auxiliary devices
+ Heating and ventilation
+ Body elements
+ Search of malfunctions
+ Specifications



Works on gear belt ГРМ

On the 4-cylinder engine the casing of a gear belt acts in film after easing of both fixing скоб.


Removal of a protective casing of gear belt ГРМ of the 5-cylinder engine after easing of both fixing скоб (arrows).


In the 6-cylinder engine the protective casing of gear belt ГРМ also is fixed fixing скобами (arrows). For removal of the right half of protective casing it is necessary to remove in addition a tension roller поликлинового a belt (the big bolt with internal шестигранником).


(2) 4-cylinder engines will pull gear belt ГРМ correctly if it can be overwound on 90 between gear wheels of a gear belt of a camshaft (1) and an intermediate shaft (the position (3) specifies in position).

Check of a tension of a gear belt of the 5-cylinder engine (an illustration at the left) and the 6-cylinder engine (an illustration on the right) occurs in the same way which has already been described in the signature to an illustration showing the 4-cylinder engine. Gear belts should be tense so that they could be turned on 90 . Illustrations show places in which it is necessary to check.


Here the thermosensitive tension roller of the 5-cylinder engine is shown.

1 and 3 – fixing bolts;
2 – шестигранник into which the key is inserted at a tension of a gear belt;
4 – a thermoelement;
5 – a fixing bolt for a tension roller (6).

At the left: a tension roller of a gear belt of the 4-cylinder engine:

1 – tightening a bolt;
2 – here it is possible to put the tool for a tension of a gear belt. The arrow shows a direction, in which it is necessary to rotate to pull a belt.

On the right: the tension roller (arrow) of the 6-cylinder engine is hidden on the right ahead on the block of cylinders.

At the left: at work with the 4-cylinder engine at installation of a gear belt marks on a gear wheel of an intermediate shaft and a mark in a pulley клиноременной transfers (on an illustration are noted by arrows) should be in one plane.

On the right: on a gear pulley of a belt of a camshaft (2) marks simultaneously should coincide with a mark-arrow (1) on a back part of a protective casing of a gear belt.


The mark of camshaft ВМТ of the first cylinder is in the 5-cylinder engine on an underside of a gear pulley. The back part of a protective casing of a gear belt is supplied by a cut (marksman) through which it is possible to check up, whether there is a mark precisely near an upper edge of a cover of a head of the block of cylinders.

At the 5-cylinder engine of mark ВМТ are located as well on pulleys of a cranked shaft. Positions (1) and (2) show marks at the established protective casing of a gear belt, a position (3) and (4) show position ВМТ at the removed protective casing of a gear belt.

At the left: drawing shows, how it is necessary to establish at the 6-cylinder engine the special tool 3243 for fixation of camshafts in position ВМТ.

On the right: on an illustration are shown the tool 3242 and a place in which it should be screwed in in the case картера for fixation of a cranked shaft.


Removal of a gear wheel of a gear belt of a camshaft from the weakened lock bolt by means of a web-footed stripper.

The drive of valves occurs, as is already mentioned, by means of a gear belt газораспределительного the mechanism. It turns a camshaft on half of turn of a cranked shaft. The gear belt results besides: the pump of a cooling liquid (model with 5 and 6-cylinder engines) and an intermediate shaft (models with 4-cylinder engines).

Removal of a casing of gear belt ГРМ

 PERFORMANCE ORDER

  1. The 4-cylinder engine: to wring out two fixing скобы above on a casing.
  2. To remove the top part of a casing.
  3. At installation to watch that the casing bottom edge has been correctly inserted into the top part, differently the casing will not keep.
  4. Usually happens to remove the top part of a casing enough. If it is necessary to remove and the bottom part:
  5. To remove клиновой a belt (see has undressed the Generator)
  6. To turn off pulleys клиноременной transfers on cranked to a shaft and the water pump.
  7. To weaken and remove lock bolts and nuts of the bottom part of a casing of a gear belt.
  8. At installation pulley bolts клиноременной are necessary for tightening transfers by the moment 20 Н•м, nuts and bolts of a casing of a gear belt the moment 10 Н•м.
  9. The 5-cylinder engine: to wring out two fixing скобы from above on a casing.
  10. To remove the top part of a casing of a gear belt.
  11. To unscrew and remove lock bolts of the bottom part of a casing.
  12. At installation to tighten all bolts the moment 10 Н•м.
  13. The 6-cylinder engine: to remove поликлиновой a belt, and also a tension roller for поликлинового a belt (has undressed the Generator).
  14. On each half of casing from above and from below to remove on one tension clamp.
  15. Cautiously to take out a casing from other fastenings.

Check of a tension of gear belt ГРМ

 PERFORMANCE ORDER

  1. To remove a casing of gear belt ГРМ.
  2. On a gear belt there should not be cracks and greasing traces.
  3. Lateral surfaces of teeths should be whole, without wear tracks.
  4. The damaged gear belt – to replace!

Check of a condition of a gear belt

 PERFORMANCE ORDER

  1. To remove a protective casing of a gear belt.
  2. The belt tension is checked on models Audi in following places:
  3. The 4-cylinder engine: between gear wheels of distributive and intermediate shaft.
  4. The 5-cylinder engine: between gear wheels of a camshaft and the pump of a cooling liquid.
  5. The 6-cylinder engine: between a gear wheel of a camshaft and the top directing roller.
  6. The cold gear belt can be curtailed at a normal tension to (braid) on 90 (right angle) only big and index fingers.

 The help: the whistling sound after start of the cold engine, amplifying at higher frequency of rotation, specifies in the too hardly tense gear belt.

Натягивание a gear belt

 PERFORMANCE ORDER

  1. The tension of a gear belt can be adjusted only at the cold engine.
  2. At first it is necessary to remove a protective casing of a gear belt.
  3. At work with the 4-cylinder engine in a workshop apply a special wrench, for example Matra V 159.
  4. To weaken a tightening bolt on a tension roller of a gear belt.
  5. Проворачивание a tension roller a wrench counter-clockwise pulls a gear belt.
  6. To tighten a tightening bolt the moment 20 Н•м.
  7. Without a wrench it is necessary to operate so: to insert a strong screw-driver into one of apertures of a gear pulley of a camshaft, a few to turn it on the left, that a gear belt ослаб.
  8. Now to weaken tightening a bolt and to put at an angle a small screw-driver. Thus it is possible to rotate the clown of a tension roller, yet the necessary tension of a gear belt until then will not be established. Naturally, during this procedure it is necessary to hold a camshaft strong. Then it is necessary to tighten tightening a bolt and once again to check up a tension of a gear belt.
  9. At work with the 5-cylinder engine slightly to weaken fixing bolts of the tension device.
  10. For натягивания a gear belt to rotate the tension device a 6-faced key the moment 25 Н•м (динамометрическим a key) clockwise.
  11. To hold the tension device in this position and again to tighten bolts the moment 10 Н•м.
  12. The 6-cylinder engine: to remove поликлиновой a belt, and also the tension device поликлинового a belt.
  13. To weaken tightening a bolt (a face key of 8 mm) on a tension roller.
  14. Key of 8 mm for internal шестигранника it is necessary to rotate a tension roller to the right until the correct tension of a gear belt will be established.
  15. To hold a tension roller in this position.
  16. The second key for internal шестигранника 8 mm to tighten tightening a bolt of a tension roller (45 Н•м).
  17. All types of engines: to turn a cranked shaft on one turn and once again to check a tension of a gear belt.

Replacement of a gear belt, regulation of phases timing

The description of operations on replacement of a gear belt is necessary not only for works on actually replacement, but also at removal and installation of a head of the block of cylinders for what it is necessarily necessary to remove a gear belt.

Installation of a gear belt by logic image includes also regulation of phases timing. But that there were no errors: phases timing do not change in the course of deterioration. They are regulated only once if before it the gear belt has been removed.

 The mechanism клапанного timing and krivoshipno-shatunnyj the mechanism work in coordination (the beginning of the head see) only at correctly established phases timing. Wrong phases timing lead to low capacity of the engine and can serve in extreme cases as the reason even the most serious damages of the engine, for example, if the piston bottom strikes in out of time closed valves. At different types of engines regulation occurs differently.

Whether it is possible to make it the hands?

Full replacement of a gear belt at 5 and 6-cylinder engines is possible only with application of special tools. Therefore, unfortunately, this work not for house conditions.

 PERFORMANCE ORDER

  1. At work with the 5-cylinder engine for removal of a gear belt it is necessary to remove демпфер in front on cranked to a shaft, and in summary again to establish it into place that is possible only with the special extension piece (2079) for динамометрического a key and противоупором (2084). At replacement carrying out only heads of the block of cylinders the belt remains not removed below on a gear wheel of the cranked shaft, therefore special tools be not required.
  2. At work with the 6-cylinder engine for regulation of phases timing (that is necessary after replacement of a gear belt and removal of a head of the block of cylinders) camshafts and a cranked shaft should be fixed precisely in position ВМТ (tools 3242 and 3243).
  3. Work with the 4-cylinder engine does not deliver problems. It is not necessary for replacement of a gear belt of special tools.

Replacement of a gear belt

The 4-cylinder engine

 PERFORMANCE ORDER

  1. To establish the piston in the first cylinder in position ВМТ of the moment of ignition, see earlier in this chapter.
  2. To remove клиновые or поликлиновые belts (has undressed the Generator).
  3. To remove a pulley on cranked to a shaft after easing of bolts with internal шестигранником (not the central bolt!).
  4. To remove a protective casing of a gear belt.
  5. To weaken a gear belt (Natjagivanie of a gear belt see) and to remove it.
  6. To put on a new gear belt. If position of gear pulleys cranked and a camshaft has not been changed, probably that phases timing are not brought down yet. But for большей confidence it is necessary to check it before definitive assemblage:
  7. To turn a gear pulley of a camshaft so that a mark in a pulley was under an arrow on a back part of a protective casing of a gear belt.
  8. If for this purpose it is necessary to turn a camshaft it can be made only in the event that any piston is not necessary in position ВМТ, valves or the bottoms of pistons differently can be damaged.
  9. To put on a gear belt gear wheels of cranked and intermediate shaft.
  10. To strengthen a bolt a pulley клиноременной transfers of a cranked shaft. Thus to watch correct position: depending on the engine version the lock pin in a pulley should or to be fixed, or fixing apertures of a pulley are located asymmetrically. In this case all fixing apertures should be in one plane with apertures of a cranked shaft.
  11. To turn a cranked shaft so that marks on a pulley клиноременной transfers showed upwards.
  12. Marks on a gear wheel of an intermediate shaft to combine with a mark in a pulley клиноременной transfers.
  13. To impose a gear belt, watching thus that position of various gear wheels has not changed.
  14. To pull a gear belt.
  15. To uncover the distributor of ignition and to check up, whether shows бегунок the distributor on a mark in edge of the case of the distributor.
  16. Otherwise to weaken the lock screw.
  17. To turn the ignition distributor so that бегунок and a mark coincided, probably, it is required to remove the distributor of ignition and again to establish it (the head ignition System).
  18. Again to tighten lock screws.
  19. Two times completely to turn the engine and once again to check up installation of phases timing.
  20. Before installation of the bottom part of a protective casing of a gear belt once again to remove a pulley клиноременной transfers of a cranked shaft.
  21. To tighten a pulley the moment 20 Н•м (correct installation see the previous text).
  22. To adjust ignition. If it is necessary to remove a gear belt only from a camshaft gear wheel to replace a head of the block of cylinders, it is possible to do without special tools. Simply it is necessary to choose necessary operations from the description.
  23. To establish the piston in the first cylinder on ВМТ the ignition moment, see in this chapter above.
  24. To remove клиновой a belt (has undressed the Generator).
  25. To remove a protective casing of a gear belt.
  26. To weaken a gear belt (Natjagivanie of a gear belt see) and to remove it.
  27. To establish противоопору 2084 on a pulley of a cranked shaft (with демпфером) to weaken the central bolt by means of the extension piece 2079.
  28. To remove a pulley with a gear belt.
  29. To note a direction of passage of a gear belt for installation. To keep passage at second-hand belts.
  30. Installation: to put on a gear belt the removed gear pulley.
  31. To establish a gear pulley of a cranked shaft together with a gear belt. To watch that the gear belt has not been clamped.
  32. To establish противоопору 2084 on a pulley of a cranked shaft (with демпфером) to tighten the central bolt by means of the extension piece 2079 (350 Н•м).
  33. Once again to check up position ВМТ of a camshaft and a cranked shaft.

The 5-cylinder engine

 PERFORMANCE ORDER

  1. On an underside of a gear pulley of a cranked shaft to combine a label with the left upper edge of a cover of a head of the block of cylinders (to observe of it through a small cut). At camshaft rotation any piston should not be in position ВМТ, valves or the bottoms of pistons otherwise can be damaged.
  2. Cranked shaft: to combine mark ВМТ in a flywheel with a mark in an observant aperture картера couplings. Or to take advantage of adjusting marks on a pulley клиноременной transfers.
  3. To put on a gear belt a camshaft, a tension roller and the water pump, thus more not to change position of distributive and cranked shaft.
  4. To pull a gear belt.
  5. To turn the engine on 2 turns and once again to check up installation of phases timing.
  6. To check up a position of the distributor of ignition as it is described for the 4-cylinder engine.
  7. To establish ignition.

The 6-cylinder engine

Here you will find the description of works, however in house conditions nothing cannot be made without special tools.

 PERFORMANCE ORDER

  1. To remove клиновой a belt together with the tension device (has undressed the Generator).
  2. To remove a protective casing of a gear belt from both parties (see in this chapter above).
  3. To turn the engine in position ВМТ of the moment of ignition of the first cylinder. Marks in a pulley of a cranked shaft and a protective casing of a gear belt should be combined, the big apertures of fixing plates on camshaft gear wheels should be directed to each other towards the engine middle.
  4. To unscrew the gauge of the moment of ignition from the block of cylinders and instead to twist the special tool a clamp of a cranked shaft 3242. The tool should enter into the aperture of a cranked shaft located behind. Slightly to tighten.
  5. To remove a pulley поликлиновой transfers of a cranked shaft, to turn off from below a protective casing of a gear belt.
  6. To designate a direction of passage of a gear belt for installation. To keep a passage direction at already used belts.
  7. To establish the special tool a clamp of a camshaft 3243 on fixing plates of camshafts.
  8. To weaken bolts of gear wheels of a camshaft on three turns.
  9. Again to remove the special tool 3243.
  10. To remove both camshafts from cones. For this purpose to apply a web-footed stripper. To establish captures on an underside of a gear wheel of a gear belt; the bolt remains as was (is weakened on three turns).
  11. After preliminary works regulation begins:
  12. If it is necessary to replace a gear belt, it becomes at once.
  13. For the further works it is necessary to put on a gear belt.
  14. Again to establish the special tool a clamp of a camshaft 3243 on lock plates of camshafts.
  15. Once again to check up special tools on correctness of installation.
  16. Gear wheels of camshafts should be so are imposed on a cone that they though could rotate together with shaft, but thus did not shake here and there (the bolt is twirled by hand).
  17. To pull now a gear belt.
  18. To tighten gear wheels of camshafts the moment 70 Н•м.
  19. To clean special tools.
  20. Again to establish the removed details.

Camshaft removal

This work is rather easy for spending on models with 4 and 5-cylinder engines. At work with the 6-cylinder engine special tools will be necessary for final installation of a gear belt.

 PERFORMANCE ORDER

  1. To remove the top part of a protective casing of a gear belt.
  2. To establish a cranked shaft in position ВМТ of the moment of ignition of the first cylinder (also see above in this chapter).
  3. To remove a gear pulley. At bolt easing to hold a gear wheel траверсой (for example, траверсой 3036). At work with the 6-cylinder engine to weaken a gear wheel of a gear belt a stripper.
  4. To uncover heads of the block of cylinders.
  5. To weaken a gear belt (Natjagivanie of a gear belt see) and to remove from a gear pulley of a camshaft.
  6. To remove from a head of the block of cylinders the additional vacuum pump for the amplifier of brakes (only the 5-cylinder engine).
  7. At the 6-cylinder engine to turn off the case of the gauge of the Hall on the left head of the block of cylinders.
  8. 4 and 5-cylinder engines: перекрестно by turns to turn on at first covers of bearings 1 and 3 (looking in front), then covers of bearings 2 and 4.
  9. The 6-cylinder engine: перекрестно by turns to turn on at first covers of bearings 2 and 3 (looking in front), then covers of bearings 1 and 4.
  10. At installation to pay attention to the following: 4 and 5-cylinder engines: to establish a camshaft so that cams at the first cylinder in regular intervals showed upwards.
  11. The 6-cylinder engine: to establish a camshaft so that a lock plate has been directed by the big aperture to an opposite head of the block of cylinders.
  12. All types of engines: the aperture of a cover of the bearing is located not in the middle: to pay attention at installation.
  13. Cover of the bearing of a camshaft to establish on the corresponding bearing according to marks.
  14. 4 and 5-cylinder engines: to tighten at first covers of bearings 2 and 4 перекрестно by turns, then covers of bearings 1 and 3. The inhaling moment: 20 Н•м.
  15. The 6-cylinder engine: to tighten at first covers of bearings 1 and 4 перекрестно by turns, then covers of bearings 2 and 3. The inhaling moment: 20 Н•м.
  16. 4 and 5-cylinder engines: to tighten a gear pulley of a camshaft (if it is removed) the moment 65 Н•м. A position at installation: the wedge on distributive to a shaft corresponds to a groove in an aperture of a gear pulley.
  17. The 6-cylinder engine: to establish a gear wheel of a camshaft with a fixing plate, to tighten the moment 70 Н•м.
  18. All types of engines: it is obligatory to check up adjustment of phases timing.
  19. After installation of a camshaft not to get the engine within 30 minutes that hydraulic pushers could "sit down".