Audi 100/A6
+ 1. Maintenance instruction
+ 2. Maintenance
+ 3. Engines
+ 3.2. Diesel engines
- 3.3. Removal and partition of engines
+ 3.3.2. Technical characteristics
3.3.3. Repair work, possible without engine dismantle
+ 3.3.4. Major maintenance
3.3.5. Removal and engine installation
3.3.6. Engine partition
+ 3.3.7. Head of cylinders
3.3.8. Pistons and rods
+ 3.3.9. Cranked shaft
3.3.10. Intermediate shaft
3.3.11. Block of cylinders
3.3.12. Radical bearings and bearings of rods
3.3.13. Piston rings
3.3.14. The first start of the engine after a partition
+ 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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Piston and rod
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1. Piston rings
2. Piston
3. Piston finger
4. Lock ring
5. Rod
6. Rod loose leaf
7. Block of cylinders
8. Rod cover
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9. Adjusting pin
10. Oil jet
11. Screw of an oil jet
12. Bolts of a cover of a rod
And – identification labels on a rod and a rod cover
In – oriyentatsionny labels |
Removal
Piston and rod
| PERFORMANCE ORDER |
| 1. Remove a head of cylinders, a flywheel, the oil pallet, the oil pump and a maslozaborny branch pipe. |
| 2. Remove a ledge in the top part of the cylinder, formed as a result of wear. |
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3. If rods and covers of rods are not marked, mark them. |
| 4. Establish N1 and N4 pistons in the bottom dead point. |
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| 5. Turn off fixing nuts, and uncover the first rod and the bearing loose leaf, mark loose leaves. |
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6. Put on pieces of a rubber tube rod bolts not to injure a neck of a cranked shaft and a cylinder wall. |
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7. Remove the loose leaf of the bearing and get a rod from above the block of cylinders. |
| 8. Remove other rods and pistons similarly. |
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| 9. Whenever possible unscrew screws and remove jets of pistons. |
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Check
Piston (AAT) head
| PERFORMANCE ORDER |
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| 1. A small screw-driver remove lock rings of a piston finger and remove a finger. Examine a finger on existence of wear and damages, at detection of damages address to experts. |
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2. Remove piston rings. Clear a piston head of deposits and clean flutes for piston rings. After removal of all deposits. Clear pistons and rods solvent and dry up them. |
| 3. Carefully examine all pistons on existence of cracks on a skirt of the piston and round a shatunny finger. Examine pistons on existence of scratches, задиров, the scorched areas or corrosion. |
| 4. Examine rods on existence of cracks and other damages. For more detailed checking of pistons and rods address to experts |
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5. Measure diameters of all four pistons. |
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6. Measure a lateral gap of piston rings. |
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7. At carrying out assembly of the piston and a rod, pay attention that the arrow on a head of the piston should indicate towards a gas-distributing belt. Labels on a rod and on a cover of a rod should be directed in a turbonagnetatel the party. |
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Check of a lubricant gap of shatunny bearings
For measurement of a lubricant gap it is possible to use an internal micrometer or other special device, but the most exact and easy method it – to use a special plastic measuring instrument.
Temporarily establish the piston in the cylinder, tighten bolts of covers of rods, and check a lubricant gap of the shatunny bearing similar to check of a lubricant gap of radical bearings.
If size of a gap do not correspond demanded, possibly, loose leaves of the wrong size are established.
Final installation of pistons and rods
Arrangement of pistons and the coding in diesel engines
| PERFORMANCE ORDER |
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1. Remove all traces of plastic. Check, that the surface of loose leaves was absolutely pure, and grease them with engine oil. |
| 2. Clean the top loose leaf of the bearing of a rod and establish it on a rod. Lubricant openings of a rod and the loose leaf should be combined. |
| 3. Clean the second loose leaf and establish it in a rod cover. |
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4. Grease pistons and rings and compress piston rings by means of the compressor of piston rings. |
| 5. Turn a cranked shaft so that the shatunny bearing of the first cylinder was in the family way the bottom dead point, and grease cylinder walls. |
| 6. Check, that the mark from above the piston was turned forward. |
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7. Press on the piston and establish it in the cylinder. |
| 8. Installation of other rods is carried out similarly. |
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9. Establish a rod on a neck of a shaft and establish a rod cover.
And – a pin (only a diesel engine)
In – an adjusting opening (only a diesel engine) |
| 10. In diesel 4th cylinder engines 1Z and AHU and 5 of cylinder ABP, AAT, AEL pistons have a special form for the best combustion of a mix and should be correctly established (see fig. An arrangement of pistons and the coding in diesel engines). |
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11. Tighten bolts till the demanded moment of an inhaling. |
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12. Hold on bolts on a demanded corner.
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| 13. After installation of all rods turn a cranked shaft several times and check ease of a course. |
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DIESEL ENGINES 1Z, AHU, AAS, ABP, AAT, AEL
| PERFORMANCE ORDER |
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13. For exact selection of thickness of laying measure ledges of pistons by means of the special tool. |
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