Four-cylinder petrol engines 1.6, 1.8 l.
Cylinder head (engine 1.6 l)
- 1 bolt, 15 Nm
- 2 bolts, 20 Nm
- 3 toothed belt rear cover
- 4 cylinder head
- 5 cylinder head bolts. Be sure to replace with new ones
- 6 oil divider
- 7 cylinder head cover gasket. If there is damage, replace with a new one. Lubricate with AUDI sealant before reinstalling "D2" - bearing cap/cylinder head transitions
- 8 reinforcing bar
- 9 cylinder head cover
- 10 bolt, 10 Nm
- 11 suction pipe top
- 12 nut, 10 Nm
- 13 oil filler cap
- 14 O-ring
- 15 ventilation unit housing
- 6 sealing gasket. If there is damage, replace with a new one.
- 17 nut, 10 Nm
- 18 holder
- 19 seal
- 20 suction pipe bottom
- 21 bolts, 20 Nm
- 22 intake manifold seal. Be sure to replace with a new one.
- 23 plug, 15 Nm
- 24 O-ring. Be sure to replace with a new one.
- 25 flange
- 26 bolt, 10 Nm
- 29 eye
- 30 cylinder head gasket
Be sure to replace with a new one. Make sure the installation is correct. After installing the cylinder head, it is necessary to replace the system with a new coolant.
You can determine the damage to the cylinder head gasket by the following signs:
- Loss of engine power
- Loss of coolant. The presence of white clouds in the exhaust gases on a warm engine.
- Oil loss.
- The coolant in the engine oil, the oil level does not decrease, but rises. Gray engine oil, bubbles on the level gauge, thin oil.
- Engine oil in coolant
- Severe foaming in the coolant.
- Lack of compression in two adjacent cylinders.
Warning: This describes the removal of the cylinder head of a 1.8L petrol engine. Separately, information is also provided for 1.6 liter engines. Since a detailed description of all operations is not possible, before removing the cylinder head, it is necessary to check once again whether all pipelines and other connections have been disconnected from and to the cylinder head.
The cylinder head should only be removed when the engine is cold (room temperature). The exhaust manifold is not disconnected, the intake manifold is removed.
Withdrawal
1. The engine should be at or below hand temperature, if necessary, wait until the engine has cooled down.
2. Disconnect the negative cable (–) battery with the ignition off.
Warning: As a result, information is erased from the electronic memory units, such as the code of the radio receiver. Without a code, the radio can only be switched on by the manufacturer or an AUDI workshop. Therefore, read the notes in the subsection Entering the radio code.
3. Drain the liquid from the cooling system, while referring to subsection Coolant replacement.
4. Remove the spark plugs.
5. Remove the air filter, while referring to subsection Removing and installing the air filter housing.
Warning: The fuel system is under pressure! Before opening the hose connections, cover them with a thick cloth. Then gently unscrew to release the pressure. Wear safety goggles, risk of injury to the eyes!
6. Disconnect the fuel supply and return lines from the fuel distribution line. At the same time, squeeze the locking keys on the clutch. To facilitate subsequent assembly, mark the pipelines.
7. Seal open pipelines with polyethylene and rubber rings to prevent contamination from entering them.
8. Disconnect the fuel injector connector and set aside.
9. Disconnect all electrical wires from the cylinder head to the body. Mark the connection with tape to reconnect when reassembling.
10. Turn away bolts of fastening and disconnect the top part of the inlet pipeline from the holder. Note: The illustration shows a 125 hp engine.
11. Turn away bolts of fastening and disconnect the inlet pipeline from a head of cylinders.
Engine 1.6 l
12. Disconnect the connector -1- at the intake manifold switching valve. Disconnect the vacuum hose -2- from the pressure regulator.
13. Remove the stoppers on the left and right at the inlet pipeline (arrow illustration).
14. Turn away bolts of fastening and disconnect the inlet pipeline from a head of cylinders.
15. Disconnect all coolant hoses from the cylinder head. To do this, open the clamps and slide them back. If necessary, mark the hoses and corresponding fittings so as not to confuse them during assembly.
16. Turn away bolts of fastening and disconnect a reception pipe with the catalytic converter from a final collector, at the same time address to subsection Removal and installation of the exhaust system.
17. Disconnect the air guide pipe from the clamp -4- and unscrew the fastening bolts -2- and -3- at the holder. Turn away bolts of fastening -1- and -5- of a thermoprotective leaf of system of pressurization behind at a head of cylinders.
18. Remove the V-belt, while referring to subsection Removing and installing ribbed V-belt.
19. Engines 1.8 l: Disconnect the V-belt tensioner, while referring to subsection Removing and installing ribbed V-belt.
20. Remove the top toothed belt guard. Establish a cranked shaft in TDC of the piston of the first cylinder, thus address to subsection Setting the piston of the first cylinder to TDC.
21. Loosen the toothed belt with the tension roller. Remove the toothed belt only at the top from the camshaft wheel, do not completely remove it, while referring to subsection Removal, installation and tension of a toothed belt.
22. Mark the position of the crankshaft pulley. To do this, paint markings on the crankshaft pulley and cylinder block. Then turn the crankshaft pulley 1/4 turn (90 °) forward or backward to prevent any piston being at TDC. Before installing the toothed belt, it is necessary to set the crankshaft back to the TDC of 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.
Engine 1.8 l
Warning: The cylinder head bolts must be loosened in the sequence numbered 1 to 10.
Engines 1.6
24. Turn out bolts of fastening of a head of cylinders. At the same time, for a 1.8 l engine, a long socket wrench of 8 mm is required (e.g. HAZET 990 2749), for engine 1.6 key for internal polyhedron (e.g. HAZET 990 Slg-12).
25. Check if all pipes and hoses leading to the cylinder head are disconnected.
26. Remove the cylinder head and install it on two wooden blocks.
27. Remove the cylinder head seal.
Installation
Warning: The new cylinder head has plastic pads to protect open valves. Linings are removed only before installation. Handle the gasket with extreme care. Damage leads to further loss of tightness.
1. Before installation, carefully clean the head and cylinder block of sealant residues with a suitable scraper. Make sure that dirt does not get into the holes of the cylinder block. Cover the holes with rags.
Warning: Be careful not to leave long marks on the surfaces after scraping. If sandpaper is used, its grit should not exceed 100.
2. Check if the holes for the cylinder head bolts contain oil, remove the oil if necessary. To do this, insert a clean rag into the holes and collect the oil with it.
Warning: If oil remains in the holes, the cylinder block may be damaged when the mounting bolts are tightened.
3. Check the deformation of the plane in various places on the cylinder head with a steel ruler and feeler gauge. Permissible deviation from flatness should not exceed 0.1 mm.
4. Checking the mating surface of the head for deformation using a steel ruler and feeler gauge.
5. After grinding the head, the size "A" must be at least as specified in the Specifications.
Warning: If the mating planes of the cylinder head are ground, the permissible minimum head height must not be less than the values \u200b\u200bpresented in the Specifications.
6. Cylinder heads with notches between valve seats or seat rings and the first threads for spark plugs can be used and repaired further without reducing their service life if the notch width does not exceed 0.5 mm.
7. Bolts of fastening and a sealing lining of a head of cylinders surely replace with new.
8. Pins for centering the cylinder head. Engine 1.8 l
9. To center the cylinder head, screw the guide pins AUDI–3070/9 into the outer holes of the cylinder head bolts with the screw tool 3070 (1.6 l engines: Guide pins AUDI–3450).
10. HAZET guide pins, No. 2570 are also available. If guide pins are not available, 2 old sheared bolts can be used. For subsequent turning out on the bolts, cut the grooves.
11. Engines 1.8 l: There are 2 pins for centering the cylinder head. Insert pins if necessary.
12. Position the new cylinder head gasket so that the marking (spare part number) was on the side of the intake manifold. Lay the gasket without sealant so that the holes remain open.
Warning: Handle gasket with care. Even minor damage can lead to leaks. A new gasket is removed from the packaging only immediately before installation.
13. With the help of an assistant, put the cylinder head in place, while watching the guide pins in the cylinder block.
14. Install the 8 cylinder head bolts with washers and tighten by hand. Bolts must be installed new.
15. Engines 1.6 l: Unscrew the mounting bolts with a screwdriver, insert the 2 remaining bolts and tighten them by hand.
Warning: Cylinder head bolts must be tightened with great care. Before tightening the bolts, check the torque wrench for accuracy. The bolts are tightened with a cold engine.
16. The fastening bolts are tightened in several stages. For each reception, the bolts are tightened in sequence from 1 to 10 by the forces given in the Specifications.
Warning: When tightening the cylinder head bolts, the angle of rotation is estimated as follows. Place the key handle along the engine and turn so that the handle is across the engine (1/4 turn = 90°).
Warning: Do not retighten the cylinder head bolts on a warm engine as part of maintenance or repair.
Warning: After installing the cylinder head, lubricate the contact surfaces of the tappets and cams with oil.
17. Set the camshaft and crankshaft to the TDC position of the piston of the first cylinder, while referring to the subsection Setting the piston of the first cylinder to TDC.
18. Before installing the cylinder head cover seal, lubricate with sealant «D2» transitions from the bearing caps to the cylinder head, as well as on the opposite side. Install the cylinder head gasket, replace the damaged gasket.
19. Place the cylinder head cover and secure it crosswise with a torque of 10 Nm.
20. Put on a toothed belt on the camshaft wheel and tighten, while referring to the subsection Removal, installation and tension of a toothed belt.
21. Attach the downpipe with the catalytic converter to the exhaust manifold, while referring to subsection Removal and installation of the exhaust system.
22. Engines with turbocharger 1.8 l (150 HP): Fasten the air supply pipe and the heat shield of the boost system behind.
23. Bolt the intake manifold crosswise with a new gasket to 10 Nm on the cylinder head.
24. Fix the inlet pipeline on the holder with a torque of 25 Nm.
25. Attach the fuel supply and return line to the distribution pipe.
26. Connect the electrical wires, for example, at the Hall sensor and at the injectors in accordance with the markings made during removal, and fasten them.
27. Engines 1.8 l: Fasten the V-belt tensioner with a torque of 25 Nm.
28. Install the V-belt, while referring to subsection Removing and installing ribbed V-belt.
29. Install spark plugs.
30. Check that all wires, fuel hoses, coolant hoses and vacuum hoses are connected as marked.
31. Check the engine oil level, fill the system with oil if necessary.
Warning: If the cylinder head was removed due to a damaged gasket, it is recommended to change the oil, including the oil in the filter, as there is coolant in the engine oil.
32. Mix new coolant and water and pour into the system, while referring to subsection Coolant replacement.
33. Install the air filter, while referring to subsection Removing and installing the air filter housing.
34. Attach the negative cable (–) to the battery.
Warning: Activate the automatic safety windows, enter the radio code, set the clock, while referring to the subsection Entering the radio code.
35. Drive a car. Then check the oil and coolant levels. Check all hose connections for tightness.
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