Removal and installation the cylinder head (Audi 80 B2)

Removal

Disconnect the wire from the negative terminal of the battery.

Remove the cap from the expansion tank. Disconnect the supply hose from the radiator and drain the coolant.

Remove the cooling system hoses if necessary.

Remove the air filter.

Disconnect the fuel supply hose from the fuel pump, and the fuel drain hose from the carburetor, and close the openings of the hoses and fittings with plugs.

Disconnect the vacuum hoses from the carburetor.

Disconnect the connectors of the electrical equipment units installed on the cylinder head, disconnect the block from the intake manifold heater.

Disconnect the engine crankcase ventilation hose from the cylinder head cover.

Disconnect the wires from the spark plugs, remove the cover and the distributor rotor.

Remove the spark plugs.

On an engine with a Solex 35 PDSIT carburetor, disconnect the throttle cable from the carburetor. On an engine with a Solex 1B1 carburetor, disconnect the throttle and air valve cables from the carburetor.

Disconnect the exhaust pipe from the exhaust manifold.

Turn the engine crankshaft to the position corresponding to the TDC of the end of the compression stroke of the piston of the 1st cylinder, aligning the mark on the crankshaft pulley with the edge of the protrusion "O" of the indicator on the cylinder block.

Remove the front timing belt cover.

Loosen the timing belt tension and remove it from the camshaft pulley.

Remove the camshaft timing pulley.

Remove the rear timing belt cover.



Remove the cylinder head cover.

Loosen the cylinder head mounting bolts.

Remove the cylinder head.

Installation

The cylinder head is installed in the reverse order of removal, taking into account the following:

• clean all removed parts and check their technical condition. Wash mating surfaces with a suitable solvent. Never clean mating surfaces with a scraper or abrasive materials. Replace sealing gaskets during assembly;
• install the cylinder head gasket so that the side of the gasket with the markings faces the cylinder head;
• install the cylinder head in place and tighten bolts 8 and 10 (see photo) to center it;
• tighten new cylinder head mounting bolts, installing new washers;
• tighten the cylinder head mounting bolts in two stages, observing the order (see photo) and tightening torques: 1st stage: 7.5 kgf·m; 2nd step: turn 90°;
• install the camshaft drive belt and adjust its tension (see above);
• check the clearances in the valve drive mechanism and adjust them if necessary;
• fill the engine cooling system with liquid,
• check the oil level in the engine crankcase;
• if the cylinder head was disassembled, adjust the ignition timing, engine idle speed, check the adjustment of the clearances in the valve drive mechanism on a hot engine.

(The full version is posted on the resource «audimanual»)