Audi 100/A6

1990-1997 of release

Repair and car operation


Audi 100/A6
+ 1. Maintenance instruction
+ 2. Maintenance
- 3. Engines
   + 3.1.1.2. Technical characteristics
   + 3.1.2. 5-cylinder engines
   - 3.1.3. 6-cylinder engines
      3.1.3.2. Gear belt
      3.1.3.3. Head of cylinders
      3.1.3.4. Valves
      3.1.3.5. Replacement of maslosjemny caps of valves
      3.1.3.6. Check of directing valves
      3.1.3.7. Fair processing of a landing facet of the saddle / valve
      3.1.3.8. Grinding in of saddles of valves
      3.1.3.9. Compression check
      3.1.3.10. Poliklinova belt
      3.1.3.11. Greasing system
      3.1.3.12. Oil pump
+ 3.2. Diesel engines
+ 3.3. Removal and partition of engines
+ 4. Cooling system
+ 5. Heating and ventilation
+ 6. Fuel system
+ 7. Exhaust system
+ 8. Systems of start, ignition
+ 9. Transmission
+ 10. Brake system
+ 11. Suspension brackets, steering
+ 12. Body
+ 13. Electric equipment
+ 14. Good advice


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3.1.3.3. Head of cylinders
GENERAL INFORMATION

Head of cylinders remove only at the cold engine (at room temperature). A final branch pipe do not disconnect. The head of cylinders can act in film without engine removal. The description belongs to the left head of cylinders. The right head of cylinders acts in film similarly.

Defects of sealing laying of a head of cylinders are determined by various signs.

Prevention

The inhaling of bolts of a head of cylinders is necessary for carrying out very carefully. Before an inhaling the dinamometrichesky key should be checked on accuracy. Bolts of a head of cylinders should be tightened on the cold engine.

Removal

PERFORMANCE ORDER
1. Unhook a drainage casing in the lower part of a motor compartment between a forward wall and a windscreen and remove it.
2. Disconnect a weight wire (–) the accumulator.
Prevention

Before a detachment it is necessary to read instructions from subsection 8.1.3.2.

With central air the accumulator is in cars under a back seat.
3. Remove a poliklinovy belt.
4. The car lift.
5. Remove the bottom casing of a motor compartment.
6. A gear belt weaken and remove from cogwheels of camshafts. A quencher of krutilny fluctuations do not remove.
7. An exhaust pipe unscrew from a final branch pipe (shooters showed an arrangement of elements of fastening).
8. Unscrew the gas pipeline at the mechanical valve of system of a retsirkulyatsiya of the fulfilled gases (AGR valve). The place of connection is at the left branch pipe near the oxygen sensor.
9. Merge cooling liquid.
10. Remove an air hose between a measuring instrument of a consumption of air and the inlet pipeline.
11. Unscrew system of ventilation of a case at the left and to the right of a head of cylinders.
12. Unscrew tubes of a supply and removal of fuel at the left and to the right of the ring pipeline from below at an inlet collector. Under a place of accession put a rag, nuts release slowly to dump pressure. Tubes muffle the corresponding jams.
13. Unfasten a cover of the exhaust silencer of noise. For this purpose insert a wrench between an inlet collector and a cover and shift it up.
14. Turn out both bolts under a cover.
15. A cover of the exhaust silencer of noise press down, pull to a branch pipe of a butterfly valve and put forward up.
16. Disconnect the following vacuum hoses. For simplification of assembly hoses previously mark by means of labels.
 – a vacuum hose to the left of a cover of the exhaust silencer of noise;
 – hose of the left connecting branch pipe of system of ventilation of a case.
17. Take out the noise exhaust silencer.
18. Mark and remove the following vacuum pipelines.
 – the vacuum pipeline of the amplifier of brake system on the right at an inlet collector and at the vacuum pump on the right head of cylinders;
 – vacuum hose from above AGR system boxes. The box with the mechanical perepuskny valve is at the left below at an inlet collector;
 – the vacuum pipeline of a box of GRA system (a black box from plastic). The GRA system carries out switching the valve of an inlet collector, the box is near an AGR system box;
 – the vacuum pipeline of the clock valve of the filter with absorbent carbon at a butterfly valve;
 – vacuum pipelines at the valve of switching of an inlet collector (blue) and at the electric valve AGR systems (brown). Both valves are under a measuring instrument of a consumption of air.
19. Unscrew by means of a natural an external shestigrannik of SW 5 at the left a cover of wires of klapanny nozzles.
20. Unfasten draft of gas, remove and put aside.
21. Remove or disconnect the following wires. For simplification of assembly of a wire mark by means of labels.
 – all tips of spark plugs;
 – all tips of klapanny nozzles;
 – the tip of the valve of stabilization of idling on the right below at an inlet collector;
 – the tip of the sensor of provision of a butterfly valve below at a butterfly valve branch pipe;
 – the tip of the sensor of pressure of oil and the hydraulic switch below at the left head of cylinders;
 – the tip of the oxygen sensor and the oxygen sensor of system of heating from an end face of the block of cylinders, near the left head of cylinders.
Prevention

Tape collar of wires release, and if necessary cut off. A collar do not remove, that at assembly of the engine it would be possible to establish a new tape collar on the same place.
22. Unscrew the mechanical valve of AGR system from an inlet collector.
23. Turn on the holder of the hydraulic pipeline and weight wires at an inlet collector on the right.

ENGINES WITH TWO VALVES ON THE CYLINDER (TO 174 HP)

Head of cylinders – the 6-cylinder petrol engine (2 valves on the cylinder, to 174 hp)
1. Bolt, 20 Nanometers
2. Inlet collector
3. Bolt, 10 Nanometers
4. Cover
5. Bolt, 10 Nanometers
6. Bolt of a head of cylinders
7. Sensor of pressure of oil, 25 Nanometers
8. Hydraulic switch, 25 Nanometers
9. Hollow bolt, 25 Nanometers
10. Bolt, 10 Nanometers
11. Case of the sensor of the Hall
12. Head of cylinders
Left and right heads of cylinders the interchangeable. Therefore before installation the head should be supplied with the corresponding cover.
13. Sealing laying of a head of cylinders

PERFORMANCE ORDER
1. An inlet collector unscrew and take out (an arrangement of fixture is shown by shooters).
2. Openings close one pure rag that dirt could not get inside.
3. Unscrew a tube of cooling liquid in the bottom of a head of cylinders.
4. Unscrew a selection tube WITH from a forward exhaust pipe and from an arm.
5. Remove the oxygen sensor.
6. Unscrew the protective thermal screen from a final branch pipe.
7. Unscrew by means of a natural an external shestigrannik of SW 5 a cover of a head of cylinders and remove together with the index of level of oil.
8. Remove sealing laying of a cover of a head of cylinders.

9. Release bolts of a head of cylinders as it should be, the return their numberings, from 8 to 1 at first on 1/2 turns, then turn out.

ENGINES WITH FIVE VALVES ON THE CYLINDER (WITH WORKING VOLUME OF 2,8 L (30 VALVES), 193 HP)

PERFORMANCE ORDER

1. Remove the tip of adjustment of a camshaft and klapanny nozzles (the arrangement of elements of fastening is shown by shooters).
2. Cut a coupling collar of wires at a cover of valves, unfasten a clip of wires at the injection highway, remove system of ventilation of a case from a cover of a head of cylinders.
3. Turn out four bolts of a fuel collector at an inlet collector.
4. Unfasten pipelines of a supply and removal of fuel from the holder.
5. Pull out and put aside a fuel collector with klapanny nozzles. Klapannye nozzles close a pure rag.
6. Unscrew ignition coils together with an arm (4 bolts).
7. Enclose under a gas pedal a wooden block in height about 90 mm. Unscrew GRA box (a regulator of speed), take out the ball hinge at a butterfly valve drive.
8. Unscrew an inlet collector.

9. Unscrew the bottom left casing of a gear belt.
10. Unscrew two bolts of a pipe of cooling liquid at a head of cylinders.
11. Check, whether all wires and the hoses going to a head of cylinders, are removed.
12. Release bolts of a head of cylinders as it should be, the return their numberings, from 8 to 1 at first on 1/2 turns, then turn out.
13. A head of cylinders remove and put on 2 wooden whetstones.
14. Remove sealing laying of a head of cylinders.

Installation

PERFORMANCE ORDER
1. Before installation a head of cylinders and the block of cylinders clear of the remains of consolidation by the corresponding shaber. Thus pay attention to that dirt did not get to openings of the block of cylinders. Openings close rags.
2. Check, whether there is no oil in openings under bolts of a head of cylinders if is, to remove. Check a head of cylinders by means of a steel ruler on a deflection. A deflection to check by means of a steel ruler and щупа in various places of a head of cylinders. The most admissible roughnesses should not exceed 0,1 mm.
Prevention

If contact surfaces of a head of cylinders to are processed, the admissible height of a doobrabotanny head should not be less than some minimum height. The minimum height of a doobrabotanny head of cylinders of 132,75 mm (for the engine with working volume of 2,8 l and 30 valves – 139,25 mm).
3. Check, whether are free from opening oil under bolts of a head of cylinders, if necessary oil remove. If there is no possibility to blow an opening the compressed air, it is necessary to take a small screw-driver and well absorbing rag and with their help to clear openings of oil.
4. Sealing laying of a head of cylinders surely replace. The inscription on laying should be turned towards a head of cylinders. Laying stack dry and on a dry surface so that openings in the block of cylinders were not closed.
5. For a centering of sealing laying and a head of cylinders there are directing plugs.
6. Reserve the correct places for directing plugs.
Prevention

If the new head of cylinders is established, it is necessary to establish in advance from a forward end face a cap. It is necessary in order that established as the spare part a head of cylinders could be established both on the right, and at the left.

7. External edge of a cap grease with AMV 1880002 hermetic. A cap by means of a core of VW-295 it is necessary заглубить so that its external edge was aflush with an adjusting facet of a head of cylinders (in drawing the cap arrangement is shown).
8. Carefully establish a head by means of a waist.
9. Insert bolts of a head of cylinders with washers and wrap them by hand. Bolts of a head of cylinders surely replace with the new.

ENGINES WITH TWO VALVES ON THE CYLINDER (TO 174 HP)

PERFORMANCE ORDER
1. Bolts of a head of cylinders are tightened in two steps. In each reception bolts tighten in sequence from 1 to 8.
Reception 1: by means of a dinamometrichesky key the moment of 60 Nanometers.
Reception 2: without interrupting a tightening, tighten in the inhaling direction on 1/2 turns (180 degrees) by means of the blocked key. It is allowed to carry out this reception as 2 inhalings on 90 degrees.
2. At an inhaling of bolts of a head of cylinders estimate a key angle of rotation. The handle of a key arrange along a head of cylinders and for one course turn it before situation, perpendicular head axes (1/4 turns make 90 degrees). Then a key turn further while the key handle will not settle down again along a head of cylinders.
Prevention

The subsequent pulling up of bolts of a head of cylinders on the heated-up engine is not required and is inadmissible. At installation on replacement of a head of cylinders with the established camshaft contacting surfaces of tarelchaty pushers and cams after installation of a head of cylinders grease.
3. Establish a gear belt.
4. Carefully by means of a small screw-driver grease with Silmate AMV 17400401 greasing four edges – an arrow – on a contact surface of a head of cylinders.
Prevention

Opening for oil – And – thus do not close.
5. Contact surfaces of sealing laying of a cover of a head of cylinders before installation easily grease with means of protection from sliding on a silicone basis of D00700001.
6. Establish a cover of a head of cylinders together with the index of level of oil and evenly tighten bolts the moment of 10 Nanometers.

ENGINES WITH FIVE VALVES ON THE CYLINDER (WITH WORKING VOLUME OF 2,8 L (30 VALVES), 193 HP)

PERFORMANCE ORDER
1. Bolts of a head of cylinders are tightened in two steps. In each reception bolts tighten in sequence from 1 to 8.
Reception 1: by means of a dinamometrichesky key the moment of 60 Nanometers.
Reception 2: without interrupting a tightening, tighten in the inhaling direction on 1/2 turns (180 degrees) by means of the blocked key. It is allowed to carry out this reception as 2 inhalings on 90 degrees.
Prevention

The subsequent pulling up of bolts of a head of cylinders on the heated-up engine is inadmissible.
2. Tighten fellings of cooling liquid and a casing of a gear belt.
3. An exhaust pipe connect to a final branch pipe.
4. Tighten a branch pipe of cooling liquid behind a head of cylinders.
5. Tighten a selection tube WITH.
6. Establish the oxygen sensor.
7. Clean a rag from inlet openings.

8. An inlet collector establish with new sealing laying. Bolts tighten in the specified sequence in four receptions. The arrow shows the direction of movement of the car.
Reception 1: 5 Nanometers;
Reception 2: 10 Nanometers;
Reception 3: 20 Nanometers;
Reception 4: 20 Nanometers.
Prevention

At the engine with working volume of 2,8 l and 30 valves an inlet collector приворачивайте only the moment of 10 Nanometers.
9. Tighten by means of a natural an external shestigrannik of SW 5 at the left a cover of wires of klapanny nozzles.
10. Insert, establish or fix according to the marking put on labels the following wires:
 – all tips of spark plugs;
 – all tips of klapanny nozzles;
 – the tip of the valve of stabilization of idling on the right below at an inlet collector;
 – the tip of the sensor of provision of a butterfly valve below at a butterfly valve branch pipe;
 – the tip of the sensor and the switch of pressure of oil below at the left head of cylinders;
 – the tip of the sensor of the Hall below at the left head of cylinders;
 – the tip of the oxygen sensor and a heater of the oxygen sensor from an end face of the block of cylinders, near the left head of cylinders.
11. Tighten the holder of the hydraulic pipeline and weight wires at an inlet collector on the right.
12. Tighten the mechanical valve of AGR system to an inlet collector.
13. Establish draft of gas.
14. Tighten at the left a cover of wires of klapanny nozzles.
15. Establish according to the marking put on labels the following vacuum pipelines:
 – the vacuum pipeline of the amplifier of brake system on the right at an inlet collector and at the vacuum pump on the right head of cylinders;
 – vacuum hose from above AGR system boxes. The box with the mechanical perepuskny valve is at the left below at an inlet collector;
 – the vacuum pipeline of a box of GRA system (a black box from plastic). The GRA system carries out switching the valve of an inlet collector, the box is near an AGR system box;
 – the vacuum pipeline of the clock valve of the filter with absorbent carbon at a butterfly valve;
 – vacuum pipelines at the valve of switching of an inlet collector (blue) and at the electric valve AGR systems (brown). Both valves are under a measuring instrument of a consumption of air.
16. Establish at a butterfly valve and tighten the noise exhaust silencer. Attach a cover of the exhaust silencer of noise.
17. Attach according to the markings put on labels the following vacuum hoses:
 – a vacuum hose to the left of a cover of the exhaust silencer of noise;
 – hose of the left connecting branch pipe of system of ventilation of a case.
18. Establish an air hose between a measuring instrument of a consumption of air and the inlet pipeline.
19. Tighten system of ventilation of a case at the left and to the right of a head of cylinders.
20. Tighten tubes of a supply and removal of fuel.
21. Tighten to a final branch pipe the pipeline of a supply of gas to the mechanical valve of system of a retsirkulyatsiya of the fulfilled gases (AGR valve).
22. Establish the bottom casing of a motor compartment.
23. Connect a weight wire (-) the accumulator. Enter a code of the anti-theft device, and also program radio stations.
Prevention

The accumulator can be connected only at the switched-off ignition, the control unit injection system otherwise fails.
24. Fasten a drainage casing, and also establish a back seat.
25. Fill in cooling liquid. Cooling liquid always update.
26. Check oil level in the engine. In case sealing laying of a head of cylinders had defect, make oil replacement.
27. The engine warm up to normal working temperature, again check level of cooling liquid, and also check places of connection of all hoses on tightness.

FEATURES OF THE RIGHT HEAD OF CYLINDERS (ONLY ENGINES IN CAPACITY OF 174 HP)

PERFORMANCE ORDER
1. Remove the vacuum pump and a cap.
2. Remove an intermediate flange.
3. Pull out the piston from a camshaft.
4. Ring sealing laying And, In, With and D replace.
5. The piston, an intermediate flange and the vacuum pump again establish and tighten the moment of 10 Nanometers.