Audi 80/Avant (B4)

since 1991-1995 of release

Repair and car operation



Audi 80/Avant
+ Technical specification
- Engines
   Basic elements
   Greasing system
   Case ventilation
   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 engine installation
+ System of production of the fulfilled gases
+ cooling System
+ Fuel tank and fuel pump
+ Air filter and airintaking channels
+ injection System
+ Coupling
+ Transmission and transmission
+ Suspension bracket and steering
+ Brake system
+ Anti-blocking system of brakes
+ Wheels and tires
+ Body electrosystem
+ ignition System
+ Lighting
+ Signalling 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 acts in film after weakening of both fixing brackets.


Removal of a protective casing of the GRM gear belt of the 5-cylinder engine after weakening of both fixing brackets (arrow).


In the 6-cylinder engine the protective casing of the GRM gear belt is also fixed by fixing brackets (arrow). For removal of the right half of a protective casing it is necessary to remove in addition a tension roller of a poliklinovy belt (a big bolt with an internal shestigrannik).


The GRM (2) gear belt of the 4-cylinder engine will pull correctly if it can be overwound on 90 ° between gear wheels of a gear belt of a 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) occurs in the same way which was already described in the signature to an illustration showing the 4-cylinder engine. Gear belts should 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 shestigrannik in whom the key is inserted at a tension of a gear belt;
4–thermoelement;
5–a fixing bolt for a tension roller (6).

At the left: 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.

At the left: at 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) should be in one plane.

On the right: markings on a gear pulley of a belt of a camshaft (2) at the same time should coincide with a mark arrow (1) in a back part of a protective casing of a gear belt.


The mark of a camshaft of VMT of the first cylinder is in the 5-cylinder engine on a reverse side of a gear pulley. The back part of a protective casing 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 a mark of VMT are located as well on pulleys of a cranked shaft. Positions (1) and (2) show marks at the established protective casing of a gear belt, positions (3) and (4) show situation VMT at the removed protective casing of a gear belt.

At the left: drawing shows, how it is necessary to establish at the 6-cylinder engine the special tool 3243 for fixation of camshafts in situation VMT.

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


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

The drive of valves occurs, as is already mentioned, by means of a gear belt of the gas-distributing mechanism. It turns a camshaft on a half of a turn of a cranked 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, differently the casing will not keep.
  4. Usually happens to remove the top part of a casing enough. If it is necessary to remove and the lower part:
  5. To remove 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 remove 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. Carefully to take out a casing from other fastenings.

Check of a tension of the GRM gear belt

 PERFORMANCE ORDER

  1. To remove a GRM gear belt casing.
  2. On a gear belt there should not be cracks and greasing traces.
  3. Lateral surfaces of teeths should 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 a protective casing 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 a camshaft and the pump of cooling liquid.
  5. 6-cylinder engine: between a gear wheel of a camshaft and the top directing roller.
  6. The cold gear belt can be curtailed at a normal tension to (braid) on 90 ° (right angle) only big and index fingers.

 Help: the whistling sound after start of the cold engine, amplifying at higher frequency of rotation, indicates the 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 a protective casing of a gear belt.
  3. At 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. Provorachivaniye of a tension roller a wrench counter-clockwise pulls a gear belt.
  6. To tighten a tightening bolt the moment of 20 N • m.
  7. Without a wrench it is necessary to operate so: to insert a strong screw-driver into one of openings of a gear pulley of a camshaft, a few to turn it on the left that the gear belt weakened.
  8. Now to weaken tightening a bolt and to put at an angle a small screw-driver. Thus it is possible to rotate the clown of a tension roller, until then the necessary tension of a gear belt yet will not be established. Naturally, during this procedure it is necessary to hold a camshaft strong. Then it is necessary to tighten tightening a bolt and once again to check a tension of a gear belt.
  9. At 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 dinamometrichesky 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 remove 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 shestigrannik it is necessary to rotate a tension roller to the right until the correct tension of a gear belt will be established.
  15. To keep a tension roller in this situation.
  16. The second key for an internal shestigrannik of 8 mm to tighten tightening a bolt of a tension roller (45 N • м).
  17. All types of engines: to turn a cranked shaft on one turn and once again to check a tension of a gear belt.

Replacement of a gear belt, regulation of phases of a gazoraspredeleniye

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 remove a gear belt.

Installation of a gear belt by logic image includes also regulation of phases of a gazoraspredeleniye. But that there were no errors: phases of a gazoraspredeleniye do not change in the course of wear. They are regulated only once if before it the gear belt was removed.

 The mechanism of a klapanny gazoraspredeleniye and the krivoshipno-shatunny mechanism work in coordination (see the beginning of head) only at correctly established phases of a gazoraspredeleniye. The wrong phases of a gazoraspredeleniye result in low engine capacity and can in extreme cases serve as the reason even 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 occurs differently.

Whether it is possible to make it the hands?

Complete 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. At work with the 5-cylinder engine for removal of a gear belt it is necessary to remove a damper in front on cranked to a shaft, and in summary again to establish it into place that is possible only with the special extension piece (2079) for a dinamometrichesky key and an antiemphasis (2084). At carrying out replacement only heads of the block of cylinders the belt remains not removed below on a gear wheel of a cranked shaft therefore special tools be not required.
  2. At work with the 6-cylinder engine for regulation of phases of a gazoraspredeleniye (that is necessary after replacement of a gear belt and removal of a head of the block of cylinders) camshafts and a cranked shaft should be fixed precisely in situation VMT (tools 3242 and 3243).
  3. Work with the 4-cylinder engine does not deliver problems. It is not necessary for replacement of a gear belt of special tools.

Replacement of a gear belt

4-cylinder engine

 PERFORMANCE ORDER

  1. To establish the piston in the first cylinder in the provision VMT of the moment of ignition, see earlier in this chapter.
  2. To remove maple or poliklinovy belts (section Generator).
  3. To remove a pulley on cranked to a shaft after weakening of bolts with an internal shestigrannik (not the central bolt!).
  4. To remove a protective casing of a gear belt.
  5. To weaken a gear belt (see. A tension of a gear belt) and to remove it.
  6. To put on a new gear belt. If the provision of gear pulleys cranked and a camshaft was not changed, it is possible that phases of a gazoraspredeleniye are not brought down yet. But for bigger confidence it is necessary to check it before final assembly:
  7. To turn a gear pulley of a camshaft so that the mark in a pulley was under an arrow on a back part of a protective casing of a gear belt.
  8. If for this purpose it is necessary to turn a camshaft, it can be made only if any piston is not necessary in situation VMT, valves or the bottoms of pistons differently 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 cranked shaft. Thus to watch the correct situation: depending on the version of the engine the lock pin in a pulley should or to be fixed, or fixing openings of a pulley are located asymmetrically. In this case all fixing openings should be in one plane with openings of a cranked shaft.
  11. To turn a cranked shaft so that marking on a pulley of klinoremenny transfer showed up.
  12. Marking on a gear wheel of an intermediate shaft to combine with a mark in a pulley of klinoremenny transfer.
  13. To impose a gear belt, watching thus 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 a distributor begunok 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 begunok and a mark coincided, probably, it is required to remove the distributor of ignition and again to establish it (head ignition System).
  18. Again to tighten lock screws.
  19. Two times completely to turn the engine and once again to check installation of phases of a gazoraspredeleniye.
  20. Before installation of the lower part of a protective casing of a gear belt once again to remove a pulley of klinoremenny transfer of a cranked 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 remove 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. Simply it is necessary to choose necessary operations from the description.
  23. To establish the piston in the first cylinder on VMT of the moment of ignition, see in this chapter above.
  24. To remove maple a belt (section Generator).
  25. To remove a protective casing of a gear belt.
  26. To weaken a gear belt (see. A tension of a gear belt) and to remove it.
  27. To establish an antisupport 2084 on a pulley of a cranked shaft (with a damper) to weaken the central bolt by means of the extension piece 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 gear pulley.
  31. To establish a gear pulley of a cranked 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 cranked shaft (with a damper) to tighten the central bolt by means of the extension piece 2079 (350 N • м).
  33. Once again to check the provision VMT of a camshaft and a cranked shaft.

5-cylinder engine

 PERFORMANCE ORDER

  1. On a reverse side of a gear pulley of a cranked shaft to combine a label with the left upper edge of a cover of a head of the block of cylinders (to watch it through a small cut). At camshaft rotation any piston should not be in situation VMT, valves or the bottoms of pistons otherwise can be damaged.
  2. Cranked shaft: to combine a mark of VMT in a flywheel with a mark in an observant opening of a case of coupling. Or to use adjusting marking on a pulley of klinoremenny transfer.
  3. To put on a gear belt a camshaft, a tension roller and the water pump, thus more not to change the provision of distributive and cranked shaft.
  4. To pull a gear belt.
  5. To turn the engine on 2 turns and once again to check installation of phases of a gazoraspredeleniye.
  6. To check a position of the distributor of ignition 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 cannot be made without special tools.

 PERFORMANCE ORDER

  1. To remove maple a belt together with the tension device (section Generator).
  2. To remove a protective casing of a gear belt from both parties (see in this chapter above).
  3. To turn the engine in the provision VMT of the moment of ignition of the first cylinder. Marks in a pulley of a cranked shaft and a protective casing of a gear belt should be combined, big openings of fixing plates on gear wheels of a camshaft should be directed to each other towards the engine middle.
  4. To unscrew the sensor of the moment of ignition from the block of cylinders and instead to twist the special tool «a clamp of a cranked shaft 3242». The tool should enter into the opening of a cranked shaft located behind. Slightly to tighten.
  5. To remove a pulley of poliklinovy transfer of a cranked shaft, to turn off from below a protective casing of a gear belt.
  6. To designate the direction of passing of a gear belt for installation. To keep the passing direction at already used belts.
  7. To establish the special tool «a clamp of a camshaft 3243» on fixing plates of camshafts.
  8. To weaken bolts of gear wheels of a 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 establish captures on a reverse side of a gear wheel of a gear belt; the bolt remains as was (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 establish the special tool «a clamp of a camshaft 3243» on lock plates of camshafts.
  15. Once again to check special tools on correctness of installation.
  16. Gear wheels of camshafts should be so imposed on a cone that they though could rotate together with shaft, but thus 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 clean special tools.
  20. Again to establish the removed details.

Camshaft removal

This work is rather easy for carrying out on models with 4-and 5-cylinder engines. At 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 a protective casing of a gear belt.
  2. To establish a cranked shaft in the provision VMT of the moment of ignition of the first cylinder (also see above in this chapter).
  3. To remove a gear pulley. When weakening a bolt to hold a gear wheel traversy (for example, traversy 3036). At work with the 6-cylinder engine to weaken a gear wheel of a gear belt a stripper.
  4. To uncover heads of the block of cylinders.
  5. To weaken a gear belt (see. A tension of a gear belt) and to remove from a gear pulley of a 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 the Hall on the left head of the block of cylinders.
  8. 4-and 5-cylinder engines: perekrestno in turn to unscrew at first covers of bearings 1 and 3 (looking in front), then covers of bearings 2 and 4.
  9. 6-cylinder engine: perekrestno in turn to unscrew 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 establish a camshaft so that cams at the first cylinder evenly showed up.
  11. 6-cylinder engine: to establish a 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. Cover of the bearing of a camshaft to establish on the corresponding bearing according to marking.
  14. 4-and 5-cylinder engines: to tighten at first covers of bearings 2 and 4 perekrestno 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 perekrestno in turn, then covers of bearings 2 and 3. Inhaling moment: 20 N • m.
  16. 4-and 5-cylinder engines: to tighten a gear pulley of a 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 a gear pulley.
  17. 6-cylinder engine: to establish a camshaft gear wheel with a fixing plate, to tighten the moment of 70 N • m.
  18. All types of engines: it is obligatory to check adjustment of phases of a gazoraspredeleniye.
  19. After installation of a camshaft not to get the engine within 30 minutes in order that hydraulic pushers could "sit down".