Audi 80/Avant (B4)

since 1991-1995 release

Repair and operation of the car



Audi 80/Avant
+ Technical specification
- Engines
   Basic elements
   Lubrication system
   Ventilation of a case
   Visual check of the engine
   Running in of the new engine
   Engine service life
   Nominal and maximum frequency of rotation
   Restriction of frequency of rotation
   Measurement of pressure of compression
   List of malfunctions
   Provorachivaniye of the engine
   Hydraulic pushers
   Works on the GRM gear belt
   List of malfunctions
   Removal and installation of a head of the block of cylinders
   Removal and installation of the engine
+ System of production of the fulfilled gases
+ Cooling system
+ Fuel tank and fuel pump
+ Air filter and airintaking channels
+ System of injection
+ Coupling
+ Transmission and transmission
+ Suspension bracket and steering
+ Brake system
+ Anti-blocking system of brakes
+ Wheels and tires
+ Body electrical system
+ System of ignition
+ Lighting
+ Signaling devices
+ Devices and auxiliary devices
+ Heating and ventilation
+ Body elements
+ Search of malfunctions
+ Specifications





Works on the GRM gear belt

On the 4-cylinder engine the casing of a gear belt is removed after weakening of both fixing brackets.


Removal of the protection cover of the GRM gear belt of the 5-cylinder engine after weakening of both fixing brackets (arrow).


The protection cover of the GRM gear belt is also fixed in the 6-cylinder engine by fixing brackets (arrow). For removal of the right half of the protection cover it is necessary to shoot in addition a tension video of a poliklinovy belt (a big bolt with an internal hexagon).


The GRM (2) gear belt of the 4-cylinder engine is tense correctly if it can be overwound on 90 ° between gear wheels of a gear belt of the camshaft (1) and an intermediate shaft (the position (3) indicates situation).

Check of a tension of a gear belt of the 5-cylinder engine (an illustration at the left) and the 6-cylinder engine (an illustration on the right) happens in the same way which was already described in the signature to the illustration showing the 4-cylinder engine. Gear belts have to be tense so that they could be turned on 90 °. Illustrations show places in which it is necessary to check.


Here the thermosensitive tension roller of the 5-cylinder engine is shown.

1 and 3 – fixing bolts;
2 – a hexagon into which the key at a tension of a gear belt is inserted;
4 – thermoelement;
5 – a fixing bolt for a tension roller (6).

Sleva: tension roller of a gear belt of the 4-cylinder engine:

1 – tightening bolt;
2 – here it is possible to put the tool for a tension of a gear belt. The arrow shows the direction in which it is necessary to rotate to pull a belt.

On the right: the tension roller (shooter) of the 6-cylinder engine is hidden on the right ahead on the block of cylinders.

Sleva: during the work with the 4-cylinder engine at installation of a gear belt marking on a gear wheel of an intermediate shaft and a mark in a pulley of klinoremenny transfer (on an illustration are noted by shooters) have to be in one plane.

On the right: at the same time markings on the cogged pulley of a belt of the camshaft (2) have to coincide with a mark arrow (1) in a back part of the protection cover of a gear belt.


The mark of the VMT camshaft of the first cylinder is in the 5-cylinder engine on a reverse side of the cogged pulley. A back part of the protection cover of a gear belt is supplied with a cut (shooter) through which it is possible to check whether there is a mark precisely near the upper edge of a cover of a head of the block of cylinders.

At the 5-cylinder engine of mark VMT are located as well on pulleys of a bent shaft. Positions (1) and (2) show marks at the installed protection cover of a gear belt, positions (3) and (4) show the provision of VMT at the removed protection cover of a gear belt.

Sleva: the drawing shows how it is necessary to install at the 6-cylinder engine the special tool 3243 for fixation of camshafts in the provision of VMT.

On the right: on an illustration the tool 3242 and the place in which it should be screwed in in the case case for fixation of a bent shaft are shown.


Removal of a gear wheel of a gear belt of the camshaft with the weakened lock bolt by means of a web-footed stripper.

The drive of valves occurs as it is already mentioned, by means of a gear belt of the gas-distributing mechanism. It turns the camshaft on a half of a turn of a bent shaft. The gear belt brings besides: the pump of cooling liquid (model with 5-and 6-cylinder engines) and an intermediate shaft (models with 4-cylinder engines).

Removal of a casing of the GRM gear belt

 PERFORMANCE ORDER

  1. 4-cylinder engine: to wring out two fixing brackets above on a casing.
  2. To remove the top part of a casing.
  3. At installation to watch that the bottom edge of a casing was correctly inserted into the top part, otherwise the casing will not keep.
  4. Usually happens to remove the top part of a casing enough. If it is necessary to remove also the lower part:
  5. To take off maple a belt (see the section Generator)
  6. To turn off pulleys of klinoremenny transfer on cranked to a shaft and the water pump.
  7. To weaken and remove lock bolts and nuts of the lower part of a casing of a gear belt.
  8. At installation bolts of a pulley of klinoremenny transfer it is necessary to tighten the moment of 20 N • m, nuts and bolts of a casing of a gear belt the moment of 10 N • m.
  9. 5-cylinder engine: to wring out two fixing brackets from above on a casing.
  10. To remove the top part of a casing of a gear belt.
  11. To unscrew and remove lock bolts of the lower part of a casing.
  12. At installation to tighten all bolts the moment of 10 N • m.
  13. 6-cylinder engine: to take off poliklinovy a belt, and also a tension roller for a poliklinovy belt (section Generator).
  14. On each half of a casing from above and from below to remove on one tension clamp.
  15. It is careful to take out a casing from other fastenings.

Check of a tension of the GRM gear belt

 PERFORMANCE ORDER

  1. To remove a casing of the GRM gear belt.
  2. On a gear belt there should not be cracks and traces of lubricant.
  3. Side surfaces of teeths have to be whole, without wear tracks.
  4. The damaged gear belt – to replace!

Check of a condition of a gear belt

 PERFORMANCE ORDER

  1. To remove the protection cover of a gear belt.
  2. The tension of a belt is checked on the Audi models in the following places:
  3. 4-cylinder engine: between gear wheels of distributive and intermediate shaft.
  4. 5-cylinder engine: between gear wheels of the camshaft and pump of cooling liquid.
  5. 6-cylinder engine: between a gear wheel of the camshaft and the top directing roller.
  6. The cold gear belt can be curtailed at a normal tension (to twist) on 90 ° (right angle) only big and index fingers.

 Hint: the whistling sound after start of the cold engine amplifying with higher frequency of rotation indicates too hardly tense gear belt.

Tension of a gear belt

 PERFORMANCE ORDER

  1. The tension of a gear belt can be adjusted only at the cold engine.
  2. At first it is necessary to remove the protection cover of a gear belt.
  3. During the work with the 4-cylinder engine in a workshop apply a special wrench, for example Matra V 159.
  4. To weaken a tightening bolt on a tension roller of a gear belt.
  5. Provorachivany a tension roller a wrench counterclockwise pulls a gear belt.
  6. To tighten a tightening bolt the moment of 20 N • m.
  7. Without wrench it is necessary to work so: to insert the strong screw-driver into one of openings of the cogged pulley of the camshaft, to turn a little it on the left that the gear belt weakened.
  8. Now to weaken tightening a bolt and to put at an angle the small screw-driver. Thus it is possible to rotate the clown of a tension roller until the necessary tension of a gear belt is established. Naturally, during this procedure it is necessary to hold the camshaft strong. Then it is necessary to tighten tightening a bolt and to double-check a tension of a gear belt.
  9. During the work with the 5-cylinder engine slightly to weaken fixing bolts of the tension device.
  10. For a tension of a gear belt to rotate the tension device a 6-faced key the moment of 25 N • m (a dynamometer key) clockwise.
  11. To keep the tension device in this situation and again to tighten bolts the moment of 10 N • m.
  12. 6-cylinder engine: to take off poliklinovy a belt, and also the tension device of a poliklinovy belt.
  13. To weaken tightening a bolt (a face key of 8 mm) on a tension roller.
  14. Key of 8 mm for an internal hexagon it is necessary to rotate a tension roller to the right until the correct tension of a gear belt is established.
  15. To keep a tension roller in this situation.
  16. The second key for an internal hexagon of 8 mm to tighten tightening a bolt of a tension roller (45 N • м).
  17. All types of engines: to turn a bent shaft on one turn and once again to check a tension of a gear belt.

Replacement of a gear belt, regulation of phases of gas distribution

The description of operations on replacement of a gear belt is necessary not only for works on actually replacement, but also at removal and installation of a head of the block of cylinders for what it is necessary to take off a gear belt.

Installation of a gear belt logically includes also regulation of phases of gas distribution. But that there were no delusions: phases of gas distribution do not change in the course of wear. They are regulated only once if before it the gear belt was taken off.

 The mechanism of valvate gas distribution and the krivoshipno-conrod mechanism work in coordination (see the beginning of the head) only at correctly established gas distribution phases. The wrong phases of gas distribution lead to low engine capacity and can serve in extreme cases as the reason even of the most serious damages of the engine, for example, if the bottom of the piston strikes in out of time closed valves. At different types of engines regulation happens differently.

Whether it is possible to make it with own hands?

Full replacement of a gear belt at 5-and 6-cylinder engines is possible only with use of special tools. Therefore, unfortunately, this work not for house conditions.

 PERFORMANCE ORDER

  1. During the work with the 5-cylinder engine for removal of a gear belt the shaft needs to remove a damper in front on cranked, and in conclusion again to establish it into place that perhaps only with the special extender (2079) for a dynamometer key and an antiemphasis (2084). When carrying out replacement only of a head of the block of cylinders the belt remains not removed below on a gear wheel of a bent shaft therefore special tools will not be required.
  2. During the work with the 6-cylinder engine for regulation of phases of gas distribution (that is necessary after replacement of a gear belt and removal of a head of the block of cylinders) camshafts and a bent shaft have to be fixed precisely in the provision of VMT (tools 3242 and 3243).
  3. Work with the 4-cylinder engine does not cause problems. Replacement of a gear belt does not require special tools.

Replacement of a gear belt

4-cylinder engine

 PERFORMANCE ORDER

  1. To install the piston in the first cylinder in the provision of VMT of the moment of ignition, see earlier in this chapter.
  2. To take off maple or poliklinovy belts (section Generator).
  3. To remove a pulley on cranked to a shaft after weakening of bolts with an internal hexagon (not the central bolt!).
  4. To remove the protection cover of a gear belt.
  5. To weaken a gear belt (see the Tension of a gear belt) and to take off it.
  6. To put on a new gear belt. If position of cogged pulleys cranked and the camshaft was not changed, it is possible that phases of gas distribution are not brought down yet. But for bigger confidence it is necessary to check it before final assembly:
  7. To turn the cogged pulley of the camshaft so that the mark in a pulley was under an arrow on a back part of the protection cover of a gear belt.
  8. If for this purpose it is necessary to turn the camshaft, then it can be made only if any piston is not necessary in the provision of VMT, differently valves or the bottoms of pistons can be damaged.
  9. To put on a gear belt gear wheels of cranked and intermediate shaft.
  10. To strengthen a bolt a pulley of klinoremenny transfer of a bent shaft. At the same time to monitor the correct provision: depending on the version of the engine the lock pin in a pulley has to or to be recorded, or fixing openings of a pulley are located asymmetrically. In this case all fixing openings have to be in one plane with openings of a bent shaft.
  11. To turn a bent shaft so that marking on a pulley of klinoremenny transfer showed up.
  12. To combine marking on a gear wheel of an intermediate shaft with a mark in a pulley of klinoremenny transfer.
  13. To impose a gear belt, watching at the same time that the provision of various gear wheels did not change.
  14. To pull a gear belt.
  15. To uncover the distributor of ignition and to check whether shows the distributor runner on a mark in edge of the case of the distributor.
  16. Otherwise to weaken the lock screw.
  17. To turn the ignition distributor so that the runner and a mark coincided, perhaps, it will be required to remove the distributor of ignition and again to establish it (the head Sistema of ignition).
  18. Again to tighten lock screws.
  19. Two times completely to turn the engine and to double-check installation of phases of gas distribution.
  20. Before installation of the lower part of the protection cover of a gear belt once again to remove a pulley of klinoremenny transfer of a bent shaft.
  21. To tighten a pulley the moment of 20 N • m (the correct installation see the previous text).
  22. To adjust ignition. If it is necessary to take off a gear belt only from a camshaft gear wheel to replace a head of the block of cylinders, it is possible to do without special tools. Just it is necessary to choose necessary operations from the description.
  23. To install the piston in the first cylinder on ignition moment VMT, see in this chapter above.
  24. To take off maple a belt (section Generator).
  25. To remove the protection cover of a gear belt.
  26. To weaken a gear belt (see the Tension of a gear belt) and to take off it.
  27. To establish an antisupport 2084 on a pulley of a bent shaft (with a damper), to weaken the central bolt by means of the extender 2079.
  28. To remove a pulley with a gear belt.
  29. To note the direction of passing of a gear belt for installation. To keep passing at second-hand belts.
  30. Installation: to put on a gear belt the removed cogged pulley.
  31. To install the cogged pulley of a bent shaft together with a gear belt. To watch that the gear belt was not clamped.
  32. To establish an antisupport 2084 on a pulley of a bent shaft (with a damper), to tighten the central bolt by means of the extender 2079 (350 N • м).
  33. To double-check the provision of VMT of the camshaft and a bent shaft.

5-cylinder engine

 PERFORMANCE ORDER

  1. On a reverse side of the cogged pulley of a bent shaft to combine a tag with the left upper edge of a cover of a head of the block of cylinders (to watch it through a small cut). At rotation of the camshaft any piston should not be in the provision of VMT, otherwise valves or the bottoms of pistons can be damaged.
  2. Bent shaft: to combine mark VMT in a flywheel with a mark in an observation opening of a case of coupling. Or to use adjusting marking on a pulley of klinoremenny transfer.
  3. To put on a gear belt the camshaft, a tension roller and the water pump, at the same time not to change the provision of distributive and cranked shaft any more.
  4. To pull a gear belt.
  5. To turn the engine on 2 turns and to double-check installation of phases of gas distribution.
  6. To check an ignition distributor position as it is described for the 4-cylinder engine.
  7. To establish ignition.

6-cylinder engine

Here you will find the description of works, however in house conditions nothing can be made without special tools.

 PERFORMANCE ORDER

  1. To take off maple a belt together with the tension device (section Generator).
  2. To remove the protection cover of a gear belt from both parties (see in this chapter above).
  3. To turn the engine in the provision of VMT of the moment of ignition of the first cylinder. Marks in a pulley of a bent shaft and the protection cover of a gear belt have to be combined, big openings of the fixing plates on gear wheels of the camshaft have to be directed to each other towards the middle of the engine.
  4. To unscrew the ignition moment sensor from the block of cylinders and instead to twist the special tool "clamp of a bent shaft 3242". The tool has to enter the opening of a bent shaft located behind. To tighten slightly.
  5. To remove a pulley of poliklinovy transfer of a bent shaft, to turn off from below the protection cover of a gear belt.
  6. To designate the direction of passing of a gear belt for installation. To keep the direction of passing at already used belts.
  7. To install the special tool "clamp of the camshaft 3243" on the fixing plates of camshafts.
  8. To weaken bolts of gear wheels of the camshaft on three turns.
  9. Again to remove the special tool 3243.
  10. To remove both camshafts from cones. For this purpose to apply a web-footed stripper. To install captures on a reverse side of a gear wheel of a gear belt; the bolt remains as was (it is weakened on three turns).
  11. After preliminary works regulation begins:
  12. If it is necessary to replace a gear belt, it becomes at once.
  13. For further works it is necessary to put on a gear belt.
  14. Again to install the special tool "clamp of the camshaft 3243" on lock plates of camshafts.
  15. To double-check special tools on correctness of installation.
  16. Gear wheels of camshafts have to be so imposed on a cone that they though could rotate together with shaft, but at the same time did not shake here and there (the bolt is twirled by hand).
  17. To pull now a gear belt.
  18. To tighten gear wheels of camshafts the moment of 70 N • m.
  19. To remove special tools.
  20. Again to establish the removed details.

Removal of the camshaft

It is rather easy to carry out this work on models with 4-and 5-cylinder engines. During the work with the 6-cylinder engine special tools will be necessary for final installation of a gear belt.

 PERFORMANCE ORDER

  1. To remove the top part of the protection cover of a gear belt.
  2. To establish a bent shaft in the provision of VMT of the moment of ignition of the first cylinder (also see above in this chapter).
  3. To remove the cogged pulley. When weakening a bolt to hold a gear wheel traversy (for example, traversy 3036). During the work with the 6-cylinder engine to weaken a gear wheel of a gear belt a stripper.
  4. To uncover a head of the block of cylinders.
  5. To weaken a gear belt (see the Tension of a gear belt) and to remove from the cogged pulley of the camshaft.
  6. To remove from a head of the block of cylinders the additional vacuum pump for the amplifier of brakes (only 5-cylinder engine).
  7. At the 6-cylinder engine to turn off the case of the sensor of Hall on the left head of the block of cylinders.
  8. 4-and 5-cylinder engines: cross in turn to turn off at first covers of bearings 1 and 3 (looking in front), then covers of bearings 2 and 4.
  9. 6-cylinder engine: cross in turn to turn off at first covers of bearings 2 and 3 (looking in front), then covers of bearings 1 and 4.
  10. At installation to pay attention to the following: 4-and 5-cylinder engines: to install the camshaft so that cams at the first cylinder evenly showed up.
  11. 6-cylinder engine: to install the camshaft so that the lock plate was directed by the big opening to an opposite head of the block of cylinders.
  12. All types of engines: the opening of a cover of the bearing is located not in the middle: to pay attention at installation.
  13. To install a cover of the bearing of the camshaft on the corresponding bearing according to marking.
  14. 4-and 5-cylinder engines: to tighten at first covers of bearings 2 and 4 cross in turn, then covers of bearings 1 and 3. Inhaling moment: 20 N • m.
  15. 6-cylinder engine: to tighten at first covers of bearings 1 and 4 cross in turn, then covers of bearings 2 and 3. Inhaling moment: 20 N • m.
  16. 4-and 5-cylinder engines: to tighten the cogged pulley of the camshaft (if it is removed) the moment of 65 N • m. A position at installation: the wedge on distributive to a shaft corresponds to a groove in an opening of the cogged pulley.
  17. 6-cylinder engine: to establish a camshaft gear wheel with the fixing plate, to tighten the moment 70 N • m.
  18. All types of engines: it is obligatory to check adjustment of phases of gas distribution.
  19. After installation of the camshaft not to start the engine within 30 min. in order that hydraulic pushers could "sit down".







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