3.5.3. Removal and installation of a head of cylinders

Head of cylinders (engine of 1.6 l)
1 – bolt, 15 N of m
2 – bolt, 20 N of m
3 – back cover of a gear belt
4 – head of cylinders
5 – bolts of fastening of a head of cylinders
Surely replace with new
6 – oil divider
7 – sealing laying of a cover of a head of cylinders. In the presence of damages replace with new. Before installation into place grease with AUDI - "D2" sealant transitions a cover bearings/head of cylinders
8 – intensifying level
9 – cover of a head of cylinders
10 – bolt, 10 N of m
11 – the top part of the soaking-up pipe
12 – nut, 10 N of m
13 – stopper of a maslozalivny mouth
14 – sealing ring
15 – case of the ventilating device		 6 – sealing laying
In the presence of damages replace with new.
17 – nut, 10 N of m
18 – holder
19 – consolidation
20 – the lower part of the soaking-up pipe
21 – bolt, 20 N of m
22 – consolidation of the inlet pipeline
Surely replace with new.
23 – stopper, 15 N of m
24 – sealing ring
Surely replace with new.
25 – flange
26 – bolt, 10 N of m
29 – eye
30 – laying of a head of cylinders
Surely replace with new. You watch correctness of installation. After installation of a head of cylinders it is necessary to replace system with new cooling liquid.

It is possible to determine damage of laying of a head of cylinders by the following signs:

– Loss of engine capacity
– Loss of cooling liquid. Existence of white clouds in the fulfilled gases on the heated-up engine.
– Oil loss.
– Cooling liquid in motive oil, the level of oil does not decrease, and raises. Gray color of motive oil, bubbles on the index of level, liquid oil.
– Motive oil in cooling liquid
– Strong foaming in cooling liquid.
– Lack of a compression in two next cylinders.

ATTENTION

Here removal of a head of cylinders of the petrol engine of 1.8 l is described. Also data concerning engines of 1.6 l are separately provided. As the detailed description of all operations is not possible, before removal of a head of cylinders it is necessary to double-check whether all pipelines and other accessions are disconnected from a head of cylinders and to it.
The head of cylinders needs to be removed only on the cold engine (room temperature). The final collector is not disconnected, the inlet pipeline is removed.

REMOVAL

PERFORMANCE ORDER
1. The engine has to have temperature not higher than temperature of a hand if it is necessary, wait until the engine is cooled.
2. Disconnect a negative cable (–) of the rechargeable battery at the switched-off ignition.
ATTENTION

Thereof information from electronic blocks of memory as, for example, a radio receiver code is erased. Without code the radio receiver can be switched on only by the manufacturer or HUNDRED AUDIS. Therefore study remarks in the subsection Input of a Code of the Radio Receiver.
3. Merge liquid from the cooling system, at the same time address the subsection Replacement of Cooling Liquid.
4. Remove spark plugs.
5. Remove the air filter, at the same time address the subsection Removal and installation of the case of the air filter.
ATTENTION

The fuel system is under pressure! Before opening of hose connections it is necessary to close them a thick rag. Then, carefully turning off, to take off pressure. Use goggles, danger of traumatizing eyes!
6. Disconnect pipelines of giving and return of fuel from the fuel distributive highway. At the same time squeeze the fixing keys on the coupling. For simplification of the subsequent assembly mark pipelines.
7. Close opened the pipeline with polyethylene and rubber rings to exclude hit of pollution in them.
8. The socket of injectors of fuel also take Rasstykuyte aside.
9. Disconnect all electric wires from a head of cylinders to a body. Mark connection by a tape to restore connection at assembly.
10. Turn off bolts of fastening and disconnect the top part of the inlet pipeline from the holder. Remark: On an illustration the engine of 125 h.p. is shown.
11. Turn off bolts of fastening and disconnect the inlet pipeline from a head of cylinders.
Engine of 1.6 l
12. Rasstykuyte the socket-1-at the valve of switching of the inlet pipeline. Disconnect a vacuum hose –2– from pressure regulator.
13. Remove stoppers at the inlet pipeline at the left and on the right (an arrow on an illustration).
14. Turn off bolts of fastening and disconnect the inlet pipeline from a head of cylinders.
15. Disconnect all hoses of cooling liquid from a head of cylinders. For this purpose open collars and shift them back. If necessary mark hoses and the corresponding branch pipes not to mix them at assembly.
16. Turn off bolts of fastening and disconnect a reception pipe with the catalytic converter from a final collector, at the same time address the subsection Removal and installation of system of release.
17. Disconnect the directing air pipe from a collar –4– and turn off bolts of fastening-2-and-3-at the holder. Turn off bolts of fastening –1– and a-5-thermoprotective leaf of system of pressurization behind at a head of cylinders.
18. Take off maple a belt, at the same time address the subsection Removal and installation of a ridge maple belt.
19. Engines of 1.8 l: Disconnect the tension device of a maple belt, at the same time address the subsection Removal and installation of a ridge maple belt.
20. Remove the top protective cover of a gear belt. Establish a bent shaft in VMT of the piston of the first cylinder, at the same time address the subsection Installation of the Piston of the first cylinder in VMT.
21. Weaken a gear belt by means of a tension roller. Take off a gear belt only above from a camshaft wheel, completely do not remove it, at the same time address the subsection Removal, installation and a tension of a gear belt.
22. Mark the provision of a pulley of a bent shaft. For this purpose apply markings with paint on a pulley of a bent shaft and the block of cylinders. Then turn a pulley of a kolonchaty shaft on 1/4 turns (90 °) forward or back to exclude finding of any piston in VMT. Before installation of a gear belt it is necessary to establish a bent shaft in VMT of the piston of the first cylinder again.
23. Turn off bolts of fastening of a cover of a head of cylinders and remove together with laying.
Engine of 1.8 l
ATTENTION

Bolts of fastening of a head of cylinders have to turn away in the sequence of numbering with 1 on 10.
Engines 1.6
24. Turn out bolts of fastening of a head of cylinders. At the same time for the engine of 1.8 l the long face key of 8 mm (for example, HAZET 990 2749), is necessary for the engine 1.6 a key under an internal polyhedron (for example, HAZET 990 Slg–12).
25. Check whether all pipelines and hoses conducting to a head of cylinders are disconnected.
26. Remove a head of cylinders and establish it on two wooden whetstones.
27. Remove a sealing head of cylinders.

INSTALLATION

ATTENTION

The new head of cylinders has plastic linings for protection of open valves. Linings are removed only before installation. Handle with laying extremely with care. Damage leads further to tightness loss.

PERFORMANCE ORDER
1. Before installation carefully clear a head and the block of cylinders the corresponding shaber of the sealant remains. You watch that dirt did not get to openings of the block of cylinders. Close openings rags.
ATTENTION

You watch that on surfaces after a shabreniye there were no risks of big length. If the emery paper is applied, granularity it should not exceed 100.
2. Check whether contain an opening for bolts of fastening of a head of cylinders oil, if necessary remove oil. For this purpose enter a pure rag into openings and collect oil with its help.
ATTENTION

If oil remains in openings, at an inhaling of bolts of fastening the block of cylinders can be damaged.
3. Check in various places of a head of cylinders by means of a steel ruler and the probe deformation of the plane. The tolerance from planeness should not exceed 0.1 mm.
4. Check of a surface of interface of a head on deformation by means of a steel ruler and the probe.
5. After carrying out grinding of a head, the and size has to be not less specified in Specifications.
ATTENTION

If the interfaced planes of a head of cylinders are ground, the admissible minimum height of a head should not be the values which were less presented in Specifications.
6. The heads of cylinders having risks between saddles of valves or rings of saddles and the first rounds of a carving under spark plugs can be applied and be under repair further without decrease in their service life if width рисок does not exceed 0.5 mm.
7. Surely replace bolts of fastening and sealing laying of a head of cylinders with new.
8. Pins for centering of a head of cylinders. Engine of 1.8 l
9. For centering of a head of cylinders screw in external openings of bolts of fastening of a head of cylinders the directing fingers of AUDI-3070/9 the tool for a vvorachivaniye 3070 (engines of 1.6 l: The directing AUDI-3450 fingers).
10. There are also directing fingers of HAZET, No. 2570. If the directing fingers are unavailable, it is possible to apply 2 old bolts of fastening with the cut-off heads. For the subsequent reversing on bolts saw through grooves.
11. Engines of 1.8 l: For centering of a head of cylinders there are 2 pins. If necessary insert pins.
12. Put new sealing laying of a head of cylinders so that marking (spare part No.) was from a branch pipe of inlet valves. Put laying without sealant so that openings remained open.
ATTENTION

Handle with laying with care. Even small damages can result in leakage. New laying is taken out from packing only just before installation.
13. Put a head of cylinders by means of the assistant into place, at the same time you watch the directing pins in the block of cylinders.
14. Establish 8 bolts of fastening of a head of cylinders with washers and tighten them by hand. Bolts are established surely new.
15. Engines of 1.6 l: Turn out fastening bolts the screw-driver, insert 2 remained bolts and tighten them by hand.
ATTENTION

The inhaling of bolts of fastening of a head of cylinders should be carried out with special care. Before an inhaling of bolts check a dynamometer key for accuracy. Bolts drag on at the cold engine.
16. Bolts of fastening drag on for several receptions. For each reception bolts drag on in the sequence with 1 on 10 efforts given in Specifications.
ATTENTION

At an inhaling of bolts of fastening of a head of cylinders the angle of rotation is estimated as follows. Put the key handle along the engine and turn so that the handle rose across the engine (1/4 turns = 90 °).

Tightening of bolts of fastening of a head of cylinders on the warm engine within carrying out maintenance or repair is not allowed.

After installation of a head of cylinders oil contact surfaces of pushers and cams.
17. Establish distributive and cranked shaft in the provision of VMT of the piston of the first cylinder, at the same time address a podazdel Installation of the piston of the first cylinder in VMT.
18. Before installation of consolidation of a cover of a head of cylinders grease with D2 sealant transitions from covers of bearings to a head of cylinders, and also on the opposite side. Put laying of a head of cylinders, replace the damaged laying.
19. Put a cover of a head of cylinders and fix it cross-wise by the moment of 10 N • m.
20. Put on a gear belt a wheel of the camshaft and pull, at the same time address the subsection Removal, installation and a tension of a gear belt.
21. Fix a reception pipe with the catalytic converter on a final collector, at the same time address the subsection Removal and installation of system of release.
22. Engines with a turbocompressor of 1.8 l (150 h.p.): Fix behind a pipe of air supply and the heat-shielding screen of system of pressurization.
23. Fix by bolts cross-wise the inlet pipeline with new laying the moment of 10 N of m on a head of cylinders.
24. Fix the inlet pipeline on the holder by the moment of 25 N of m.
25. Fix the pipeline of giving and return of fuel on a distributive pipe.
26. Connect electric wires, for example, at Hall's sensor and at injectors according to the markings put at removal, and fix them.
27. Engines of 1.8 l: Fix a natyazhitel of a maple belt by the moment 25 N of m.
28. Establish maple a belt, at the same time address the subsection Removal and installation of a ridge maple belt.
29. Establish spark plugs.
30. Check whether all wires, fuel hoses, hoses of the cooling system and vacuum hoses according to the put markings are attached.
31. Check oil level in the engine, if necessary fill system with oil.
ATTENTION

If the head of cylinders was removed owing to laying damage, it is recommended to make oil replacement, including oil in the filter as in motive oil there is a cooling liquid.
32. Mix new cooling liquid and water and fill in in system, at the same time address the subsection Replacement of Cooling Liquid.
33. Install the air filter, at the same time address the subsection Removal and installation of the case of the air filter.
34. Attach a negative cable (–) to the rechargeable battery.
ATTENTION

Make active automatic equipment of safety of window regulators, enter a radio receiver code, establish hours, at the same time address the subsection Input of a Code of the Radio Receiver.
35. Pass on the car. After that check the level of oil and cooling liquid. Check all hose connections for tightness.