Audi A3

Since 1997 of release

Repair and car operation



Audi A3
+ The maintenance instruction
+ Current leaving and service
- The engine
   Compression check in engine cylinders
   Check of the engine by means of the vacuum gauge
   Removal and installation of the bottom cover of an impellent compartment
   Removal and engine/rkpp installation
   - Four-cylinder petrol engines 1.6, 1.8 l
      Installation of the piston of the first cylinder in ВМТ
      Removal, installation and tension of a gear belt
      Removal and installation of a head of cylinders
      Removal and installation ridge клинового a belt
   + Diesel engines
   + Major repairs
   + Greasing system
+ Systems of cooling, heating
+ The power supply system and release of the fulfilled gases
+ Engine electric equipment
+ Manual box of a gear change
+ Automatic transmission and models with a full drive
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Electroschemes





Removal and installation of a head of cylinders

THE GENERAL DATA

Head of cylinders (the engine 1.6)

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

To define damage of a lining of a head of cylinders it is possible to following signs:

– Loss of capacity of the engine
– Loss of a cooling liquid. Presence of white clouds in the fulfilled gases on the heated-up engine.
– Oil loss.
– The cooling liquid in impellent oil, oil level does not decrease, and raises. Grey colour of impellent oil, vials on the level index, liquid oil.
– Impellent oil in a cooling liquid
– Strong foaming in a cooling liquid.
– Absence 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 resulted also. As the detailed description of all operations is not obviously possible, before removal of a head of cylinders it is necessary to check up once again, whether all pipelines and other joinings 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 the 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 the manufacturer or HUNDRED AUDI. Therefore familiarise with remarks in subsection Input of a code of a radio receiver.


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

ATTENTION

The fuel system is under pressure! Before opening шланговых connections it is necessary to close their thick rag. Then, cautiously turning on, to remove pressure. Use goggles, danger травмирования an eye!


6. Disconnect pipelines of giving and return of fuel from a fuel distributive highway. Thus compress fixing keys on муфте. For simplification of the subsequent assemblage mark pipelines.
7. Close opened the pipeline polyethylene and rubber rings to exclude hit in them of pollution.
8. Расстыкуйте a socket of injectors of fuel also take aside.
9. Disconnect all electric wires from a head of cylinders to a body. Mark connection by a tape to restore connection at assemblage.
10. Turn away bolts of fastening and disconnect the top part of the inlet pipeline from the holder. The remark: On an illustration the engine of 125 h.p. is shown
11. Turn away bolts of fastening and disconnect the inlet pipeline from a head of cylinders.
The engine of 1.6 l
12. Расстыкуйте a socket–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 marksman on an illustration).
14. Turn away bolts of fastening and disconnect the inlet pipeline from a head of cylinders.
15. Disconnect all hoses of a cooling liquid from a head of cylinders. For this purpose open collars and shift them back. If necessary mark hoses and corresponding branch pipes not to mix them at assemblage.
16. Turn away bolts of fastening and disconnect a reception pipe with catalytic the converter from a final collector, thus address to subsection Removal and installation of system of release.
17. Disconnect directing pipe of air from a collar–4 and turn away bolts of fastening–2 and–3 at the holder. Turn away bolts of fastening–1 and–5 thermoprotective sheets of system of pressurisation behind at a head of cylinders.
18. Remove клиновой a belt, thus address to subsection Removal and installation ridge клинового a belt.
19. Engines of 1.8 l: Disconnect the tension device клинового a belt, thus address to subsection Removal and installation ridge клинового a belt.
20. Remove the top protective cover of a gear belt. Establish a cranked shaft in ВМТ the piston of the first cylinder, thus address to subsection Installation of the piston of the first cylinder in ВМТ.
21. Loosen the 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 subsection Removal, installation and a tension of a gear belt.
22. Mark position of a pulley of a cranked shaft. For this purpose put marks by a paint on a pulley of a cranked shaft and the block of cylinders. Then turn a pulley колончатого a shaft on 1/4 turns (90 ░) forward or back, to exclude a finding of any piston in ВМТ. Before installation of a gear belt it is necessary to establish again a cranked shaft in ВМТ the piston of the first cylinder.
23. Turn away bolts of fastening of a cover of a head of cylinders and remove together with a lining.
The 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 of 8 mm (for example, HAZET 990 2749), the long face key is necessary for the engine 1.6 key under an internal polyhedron (for example, HAZET 990 Slg–12).
25. Whether check up 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 бруска.
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 a lining extremely cautiously. Damage results further in tightness loss.


PERFORMANCE ORDER
1. Before installation a head and the block of cylinders cautiously clear corresponding шабером of the hermetic rests. Watch that the dirt has not got to apertures of the block of cylinders. Close apertures rags.
ATTENTION

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


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

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


3. Check up in various places of a head of cylinders by means of a steel ruler and probeа plane deformation. The maximum deviation 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 probeа.
5. After carrying out of polishing of a head, the size "and" should be not less specified in Specifications.

ATTENTION

If 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 coils 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 a sealing lining of a head of cylinders necessarily replace with the new.
8. Pins for a centering of a head of cylinders. The engine of 1.8 l
9. For a centering of a head of cylinders screw in external apertures of bolts of fastening of a head of cylinders directing fingers AUDI–3070/9 the tool for вворачивания 3070 (engines of 1.6 l: Directing fingers AUDI–3450).
10. There are also directing fingers HAZET, № 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 a new sealing lining of a head of cylinders so that marks (№ spare parts) were from outside a branch pipe of inlet valves. A lining without hermetic put so that apertures remained opened.
ATTENTION

Address with a lining cautiously. Even small damages can lead негерметичности. The new lining 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 necessarily 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 carefulness. Before an inhaling of bolts check up динамометрический a key on accuracy. Bolts are tightened at the cold engine.


16. Fastening bolts are tightened for some receptions. For each reception bolts are tightened in sequence with 1 on 10 efforts resulted 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 handle of a key along the engine and turn so that the handle has risen across the engine (1/4 turns = 90 ░).

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

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


17. Establish distributive and cranked shaft in position ВМТ of the piston of the first cylinder, thus address to подазделу Installation of the piston of the first cylinder in ВМТ.
18. Before installation of consolidation of a cover of a head of cylinders grease with hermetic źD2╗ transitions from covers of bearings to a head of cylinders, and also on an opposite side. Put a lining of a head of the cylinders, the damaged lining replace.
19. Put a cover of a head of cylinders and fix it cross-wise the moment 10 Н•м.
20. Put on a gear belt a wheel of a camshaft and pull, thus address to subsection Removal, installation and a tension of a gear belt.
21. Fix a reception pipe with catalytic the converter on a final collector, thus address to subsection Removal and installation of system of release.
22. Engines with турбокомпрессором 1.8 l (150 h.p.): Fix behind a pipe of giving of air and the heat-shielding screen of system of pressurisation.
23. Fix bolts cross-wise the inlet pipeline with a new lining the moment 10 Н m on a head of cylinders.
24. Fix the inlet pipeline on the holder the moment 25 Н m.
25. Fix the pipeline of giving and fuel return on a distributive pipe.
26. Connect electric wires, for example, at the gauge of the Hall and at injectors according to the marks put at removal, and fix them.
27. Engines of 1.8 l: Fix натяжитель клинового a belt the moment 25 Н m.
28. Establish клиновой a belt, thus address to subsection Removal and installation ridge клинового a belt.
29. Establish spark plugs.
30. Check up, whether all wires, fuel hoses, hoses of system of cooling and vacuum hoses according to the put marks are attached.
31. Check up in the engine oil level, if necessary fill system with oil.

ATTENTION

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


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

ATTENTION

Make active safety automatics Glass lifts, 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 up level of oil and cooling liquid. Check up on tightness all шланговые connections.
On the main page