Cylinder head. Petrol engine 1.6 l ALZ
- 1 - Cover
- 2 - Seal. Replace if damaged
- 3 - Oil separator
- 4 - Holder
- 5 - Screw, 10 Nm
- 6 - Seal. Be sure to replace
- 7 - Screw, 10 Nm
- 8 - Connecting pipe
- 9 - Eye
- 10 - Screw, 20 Nm
- 11 - Sealing gasket of the cylinder head. Be sure to replace After replacing the gasket, it is necessary to replace the coolant.
- 12 - Cylinder head. Check for deformations. Permissible flatness: 0.1 mm. After replacing the cylinder head, the coolant must be replaced. Minimum height after processing: 132.6 mm.
- 13 — Bolt of fastening of a head of cylinders. Be sure to replace. The Polydrive bolts are unscrewed and screwed in using the AUDI-3452 or HAZET 2779-9 tool. Follow the sequence of loosening and tightening the bolts.
- 14 - Sealing gasket. Replace if damaged.
- 15 - Cylinder head cover
- 16 - Bolt with remote bushing, 10 Nm. Tightening sequence from inside to outside crosswise
- 17 - Screw, 10 Nm
- 18 - Ventilation connection to the expansion tank
- 19 - O-ring. Be sure to replace. This process requires some experience. Therefore, only the most important instructions for the experienced mechanic are described here.
General instructions
Be sure to replace the cylinder head bolts, self-locking nuts, torque wrench bolts, and O-rings and gaskets.
If a replacement cylinder head is being installed, all contact surfaces between bearings, roller levers and camshaft cam sliding surfaces must be lubricated before installing the cylinder head cover.
The plastic seals protecting the open valves may only be removed before installing the cylinder head.
If the cylinder head is replaced, the coolant must be replaced.
Withdrawal instructions
1. The cylinder head is removed only on a cold engine (not above body temperature).
2. Remove V-belt and tensioner.
3. Remove the toothed belt, refer to Section Removal and installation of a gear belt.
4. The fuel system is under pressure! Cover the connection with a thick cloth before disconnecting the hoses. Then, carefully loosen the hose to relieve the pressure.
5. After opening the fuel lines, close the holes to prevent dirt from entering the fuel system.
6. Remove the inlet pipeline.
7. When removing the exhaust pipe of the exhaust system, make sure that the docking element in the exhaust pipe is not bent by more than 10°.
8. Turn away bolts of fastening of a cover a head of cylinders crosswise.
9. Turn away bolts of fastening of a head of cylinders in sequence from 1 to 10 at first on a half-turn, and then in the same sequence completely.
Installation instructions
1. If there are cracks between the valve seats or between the seat and the threaded hole for the spark plug, the cylinder head can be used further if the crack width does not exceed 0.3 mm or only the first 4 threads are affected.
2. No oil or coolant is allowed in the blind holes for the cylinder head bolts in the cylinder block. Remove oil or liquid with a rag and a screwdriver.
3. Take out a new lining of a head of cylinders from packing just before installation.
4. Handle the gasket with extreme care. Damage to the gasket leads to loss of tightness.
5. Carefully clean the sealing surfaces of the cylinder head and block. At the same time, make sure that there are no grooves or long scratches on the surfaces (when using sandpaper, its grain size should not exceed 100 units.).
6. Carefully remove the remnants of sandpaper.
7. If the crankshaft was turned during the work - set the piston of the first cylinder to the TDC position and turn the crankshaft back a little again, refer to Section Removal and installation of a gear belt.
8. Before installing the cylinder head, set the crankshaft and camshafts to the TDC position of the first cylinder, refer to Section Removal and installation of a gear belt.
9. For centering, insert a guide mandrel AUDI-3450/2A or HAZET 2571-5 into the front outer hole for the cylinder head bolts.
Caution: Before installing the cylinder head, check that the guide mandrel can be pulled up. If necessary, slightly grind the notch of the guide mandrel.
10. Install a new seal so that the inscription on it (part number) could be read.
11. Establish a head of cylinders, insert the remained 8 bolts of fastening and tighten them by hand.
12. Unscrew the guide mandrel through the bolt holes by turning it to the left.
13. Insert the remained 2 bolts of fastening of a head of cylinders and also tighten them by hand.
14. Tighten the cylinder head bolts in sequence from 1 to 10 given in Specifications efforts.
15. Further installation is carried out in the reverse order of removal.
16. Reinstall the toothed belt and adjust the valve timing.
17. Install V-belt and tensioner.
18. Replace coolant.
Cylinder head. Petrol engine 1.8 l
- 1 - Sealing gasket of the cylinder head. When installing, the part number must point towards the cylinder head. After replacing the gasket, it is necessary to replace the coolant
- 2 - Cylinder head. After replacement, it is necessary to replace the coolant. Minimum height: 139.20 mm.
- 3 - Oil separator
- 4 — Bolt of fastening of a head of cylinders
- 5 - Cylinder head cover
- 6 - Ignition coil
- 7 - Cover
- 8 - Seal. Replace if damaged or leaking
- 9 - Nut, 10 Nm. Tighten the inner nuts first, then the outer nuts, tightening crosswise
- 10 - Seals of the cylinder head cover. Replace if damaged or leaking. Before installation, the transitions are sealed with AUDI sealant «AMV 174 004 01».
- 11 - Seal. Be sure to replace
- 12 - Combined secondary air supply valve, with pipe
- 13 - Bolt, 10 Nm
- 14 - Flange with coolant temperature sensor
- 15 - Bolt, 10 Nm
- 16 - O-ring. Be sure to replace
Hinged elements of a head of the block of cylinders. Petrol engine 1.8 l
- 1 - Sealing gasket. Observe the correct installation position. Be sure to replace
- 2 - Nut, 10 Nm
- 3 - Bolt, 10 Nm
- 4 - O-ring injector. Be sure to replace
- 5 — the Fuel distributive highway with injectors
- 6 — the Top pipe of a cooling liquid
- 7 - Bolt, 10 Nm
- 8 - Bolt, 10 Nm
- 9 — a sealing ring of the top pipe of a cooling liquid
- 10 - Bolt, 10 Nm
- 11 — the Inlet pipeline
- 12 - Bolt, 20 Nm
- 13 — a support of the inlet pipeline
General instructions are the same as for the ALZ 1.6l petrol engine. The illustrations show the AVJ/BFB petrol engine. The design of the 2.0 liter gasoline engine is similar.
Double bearing cap/cylinder head seal
1. Engine 1.8 l: Lubricate the points indicated by the arrows on the upper sealing surface of the cylinder head with a small amount of sealant, e.g. AMV 174 004 01.
Sealing of the mating points of the camshaft adjustment mechanism and the cylinder head
1. Engine 1.8 l: Lubricate the points indicated by the arrows on the upper sealing surface of the cylinder head with a small amount of sealant, e.g. AMV 174 004 01.
Removing the cylinder head cover
1. Remove nuts (arrows on the accompanying illustration) securing the cylinder head cover and remove the cover.
Tightening the cylinder head bolts
1. When tightening the cylinder head bolts, the sequence is reverse to disconnection, i.e. from 10 to 1.
2. Tighten the cylinder head bolts in the sequence from 1 to 10 specified in Specifications efforts.
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