Audi 100
Audi 100
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Service.
Workshop Manual Audi 100 1991 ...
En~ine AAN
co e
B kl 5 Cyl. F.I. engine
00 ef (4-valve, turbo) Mechanics Edition 07.91
Service Department. Technical Information
Service.
List of Workshop Manual Repair Groups Audi 100 1991 ....
Engine code
IAAN I
I
J
1
I
I
I
I
I
B kl t 5 Cyl. F.I. Engine (4-valve, Turbo), Mechanics 00 e Edition 07.91
When filing a Technical Bulletin enter the Bulletin No. in the adjacent column.When using the Workshop Manual you can then see at a glance whether Technical Bulietir)S have been published in respect of the particular Repair Group in which you are looking.
Repair Group Technical Bulletins
00 Technical Data
10 Removing and installing engine <
13 Crankshaft group
15 Cylinder head, Valve gear
17 Lubrication
19 Cooling
20 Fuel supply system
21 Charging
26 Exhaust system Technical Information should always be available to all foremen and mechanics, because their compliance with the instructions given is essential to ensure vehicle roadworthiness and safety.
In addition, the normal safety precautions to he observed when working on motor vehicles are also applicable.
This Workshop Manual is only intended for use within the Volkswagen and Audi organisation, passing on to third parties is not permitted.
Printed in Germany 000.5261.29.20
© 1991 Volkswagen AG
--------------------------
00 Technical Data - Engine code
- List of engines
10 Removing and Installing Engine - Rules for cleanliness
- Safety measures
- Removing
- Securing engine to repair stand
- Installing
- Tightening torques
13 Crankshaft Group
Dismantling and assembling engine
- Removing and installing ribbed belt
- Removing and installing toothed belt
Dismantling and assembling cylinder block, crankshaft and flywheel - Measuring distance from lug to ignition firing point sender (-G4)
distance from flywheel to engine speed sender (-GZ8) - Crankshaft dimensions
~ Checking crankshaft radial clearance Dismantling and assembling pistons and conrods - Piston and cylinder dimensions
- Checking conrad radial clearance
Checking basic mechanical adjustment of engine
15 Cylinder Head, Valve Gear
Removing and installing cylinder head - Installing cylinder head
- Checking compression pressure
Servicing valve gear
" Checking hydraulic bucket tappets - Renewing camshaft oil seal
- Removing and installing camshafts
- Reworking valve seats
- Renewing valve guides
- Renewing valve-stem oil seals
- (with cylinder head installed)
- Renewing valve-stem oil seals
(with cylinder head removed)
17 Lubrication
RemDving and;installing lubrication system components - Checking oil pressure switch and oil pressure
- Checking oil pressure sender (-G10)
- Removing and installing oil sump
- Removing and installing oil pump
19 Cooling
Removing and installing cooling system components - Draining and filling coolant
- Checking coolant system for leaks
- Checking pressure relief valve in cap
- Checking viscous fan
Checking turbocharger thermoswitch -F98 and coolant pump
Page
00-1
00-2
Page
10-1
10-1
10-2
10-22
10-23
10-25
Page
13-1
13-1
13-6
13-17
and
13-25
13-27
13-28
13-29
13-37
13-38
13-39
Page
15-1
15-6
15-7
15-9
15-16
15-18
15-20
15-24
15-27
15-29
15-31
Page
17 -1
17-8
17-10
17-12
17-14
Page
19-1
19-10
19-14
19-14
19-15
111-16 20 Fuel Supply System
Removing and installing fuel system components
- Rules for cleanliness when working on fuel suppl~/injection
- Safety measures when working on fuel tank
- Removing and installing fuel gauge sender
- Removing and installing fuel pump
- Removing and installing fuel tank
Dismantling and assembling fuel pump - Checking fuel pump
- Checking non-return valve of fuel pump
Servicing fuel tank ventilation with activated charcoal filter Servicing throttle linkage
- Adjusting throttle cable
21 Turbocharging
Removing and installing turbocharger components
- Rules for cleanliness when working on turbocharger
- Removing and installing turbocharger
- Checking turbocharger and waste gate
- Checking overrun cut-off valve with vacuum pump V.A.G 1390
Removing and installing intercooler components - Removing and installing intercooler
Page
20-1
system 20-4
20-5
20-6
20-8
20-11
20-11
20-13
20-17
20-19
20-22
20-23
Page
21-1
21-4
21-5
21-10
21-13
21-14
21-16
Page
26-1
26-7
26-8 26 Exhaust System
Removing and installing exhaust system components - Aligning exhaust system tension-free
- Checking exhaust system for leaks
TECHNICAL DATA <II ENG I NE CODE
Engine code and serial number dre stamped on right-hand. side at rear of cyllnder head.
00-1
LIST OF ENGINES
~n9ine CDg~ AAN Engjn~ .Qd~ AAN
Engine charadter i strcs
Manufactured from 07/91 Val ve tim; ng
for I IllIl valve lift
to - and 0 IllIl valve clearance:
Inlet opens afterTDC 3"
No. of cyl i nders 5 Inlet closes after BDC 25'
Outlet opens before BDC 42'
Dj sp 1 aceaent ltr. 2.226 Outl et cl oses before TOC 9'
Output kW/rpm 169/5900 RON at least 95
Inrque Nm/rpm 350/1950 F"el injection sy,tem Matranic
Bore mm di a , 81.0 Exha~st gas recirculation ---
Stroke mm 86.4 Cata lyst 2 x
Compression ratio 9.3 Lambda contral x
Exhau,l-gas turbocharger x
Vehi cle espect a l1y Low po 11 utant
tuned for: ex haust 00-2
REMOVING AND INSTALLING ~NGINE RULES fOR CLEANLINESS
o Troroughly cl ean all umons and scrrounding areas before dl sconnect i ng;
o Place f€moved parts on clean surface and cover with fi 1m or paper. Do not use fluffy c lotns l
o Carefully cover or seal opened components if fepai rs cannot be carried out immediat~ly.
o Only inste l l clean parts.
- Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
o When fue I system is open:
- DD not WOf! wi th compressed air If avoidaoie.
- DD nat move yehi c 1 e un I e55 absolutely
,. necessary.
SAFETY MEASURES
1 n order to avo i d i nj uri es to persons and/or destruct i on of i gnit i on and fuel i ojecli on system, observe fa II owi ng:
o On I y oi sconnect and connect wi res of Matronic ignition and fuel injection system, and measuring ~ires, with ignition swi tched off.
10-1
Engi ne is removed upward without gearbox. All cable ties reroved or cut open duri ng engi ne removal must be refi tted i n ~ ~ when installing.
Imgortant!
If radi a with anti - theft security cod i ng is fi tted, ascertai n code number before
di sconnectt ng battery.
- Di sconnect battery earthi ng strap.
IiiliL
On vehicles without fresh air filter or air conditioner, battery is located in plenum chamber on ri ght. On vehi c l es with fresh ai r filter or air conditioner, it is installed under rear seat cush i on.
10-2
i
i!
.... - Remove noise insulation -arrows-.
Disengage additional front retaining clips in centre of noise i nsul at icr .
Remove front bumper - see Wo rkshop Manual Audi lGO "Genera I Body Repai rs", Repair Group 63.
- Remove lock carri er plate - see florkshop Manual Audi 100 "General Body Repairs", Repa i r Group 50.
- Position oi I catch pan VW 1306 under engine compartment.
Open plug on coo I ant expars i on tank .
.... - Turn qui ck fasteners -arrcss- on connector cover on rear engine compartment bulkhead 90' to I eft a nd remove cover.
10-3
.... - Plug water hoses to heater with special hose clamps 3094 •
.. - Drain coolant at cooler -arrow-, pushing auxiliary hose onto drain cock if necessary.
10-4
... - Unscrew, right air dirct at radiator "-arrowsand remove.
Vehi cl os without air conditioner
... - Remove oil cooler for hydraul i c oil at rad i ator -1- and hang up on body (hoses rema·i n connected).
- Di sconnect water hoses at radi ator.
- Remove rad: ator -2-.
10-5 .
Vehicles with air conditioner
a Radiator remains installed .
... - Unscrew bracket for trim plate -2- on right-hand vehicle side.
-Unscrew ri ght and I eft radi ator attachment
-3- .
Unscrew left air guide at radiator -1- .
... - Attach support device 3251 to right-hand bumper bracket and swing radiator forward.
10-6
". ~ Disconnect air hose between air volume sensor and turbocharger -4- at a i r vel ume sensor.
Pu II off connector at air YO I ume sensor -3- .
Unscrew retaining bolt -1-.
- Loosen four spr i ng c lips -2-.
- Remove upper section of air cleaner housing and fi Iter.
Di sconnect intake hose and ta ke out lower section of air cleaner housing.
". - Disconnect upper hose to radiator -2- at radiator and cool ant mani fold and put aside. T-piece to expansion tank remains connected.
- Pull off cover -1- above ribbed bel t.
- Pu II off connector at thrott I e va I ve swi tch
-3- .
Remove air hose -4-.
10-7
". - Unscrew viscous fan. Use spanner wrench 3212 to brace.
- Loosen bolts on be 1t pu II ey of vane pump for power steeri ng.
". - Slacken ribbed belt by turning tensioning device in direction of arrow with open-end spanner and inserting pin 3204 into hole.
- Remove ri bbed be It.
- Remove belt pulley of vane pump for power s teeri ng.
- Take hose to vane pump out of bracket on I eft engi ne mount.
- Remove vane pump for power steer; n9 and set as ide in engi ne compartment. Hoses remain connected.
10-8
.. - Pull off connectors -arr cws- at:
o Thermoswi tch - 2-pi n
o Thermoswitch - 4-pi n
o Oi I pressure ,wi tch [white)
o Oil pressure gauge sender
- Pull off or unscrew wi res from alternator and loosen cabl e clip.
Vehicles with air conditioner:
.. - Unscrew retai ni ng c lip for refr; gerant and coolant pipe -arrow-.
Vehicles without air conditjoner:
- Unscrew retai ni ng tab for upper coolant pi pe -a rrow-.
10-9
.. - Detach throttl e cable -3-.
- Pu II off connector at i d ling speed stabil i zat i on va I ve -2-.
- Pull off connector and supply hose at so 1 enoi d ve I ve for act i va ted cha rcoa I fi iter -1- •
.. - Mark connectors on rear engine compartment bul khead and separate:
1- Black plug (3-pin) to right ignition unit
(2 pi ns connected in plug)
2- Brown plug (3-pin) to left ignition unit 3- Black round plug (single) to Lambda probe 4- Black plug (Z-pin) to Lambda probe
5- White plug (3-pin) to ignition coils in cyl tnder head (lower plug section 3-pin) 6- White plug (3-pin) to ignition coils in cy1 i nder head (2 pi ns connected in lower plug section)
7- Black plug (3-pin) to ignition firing
poi nt sender
8- Grey plug to speed sender
9- Brown plug to front knock sensor 10- Blue plug to rear knock sensor
10-10
r
<III - unscrew pre~sure sensor -1- on throttle
nous: ng.
Pu 11 off connector to e 1 ectri c coolant pump -2- and to Hall sender -3-.
Pu'l through wiring loom toward rear and expose.
<III - Unscrew injector cover.
Pull connectors off injectors and expose wiring loom.
- Unscrew earthing wires.
o On upper intake manifold, wiring colour brown/red
On rear intake manifold, wiring colour brown/whi te
Pull connector off thermoswi ten at back side of cylinder.
Remove coolant hoses to heater on engine.
10-11
<III - Separate fue 1 and vacuum pi pes -arrows-.
<III - To avoid damage, unscrew speed sender above
flywheel -arrow-.
10-12
.. - Unscrew bolts on engine/gearbox flange accessible from above -arrows-.
- One engine/gearbox bolt remains screwed in hand-tight.
<Ii - Pu 11 connector of sol enoi d va he for charge pressure limiting -arrow-.
10-13
.. - Remove pressure pi pe between turbocharger and i ntercoo 1 er -errovs-.
.. - Remove starter -arrows-.
10-14
Vehi cl es with automati c gearbox;
... Unscrew 3 bolts of torque converter in opening of removed starter (turn crankshaft 113 turn each time),
... - Unscrew earthi ng wi re -1- from ri ght longitudinal member.
Mark oil pipes -2- and unscrew from oil fi Iter fl anqe, a II owi ng oi I to dri pinto catch pan,
10-15
Vehicles with ajr conditioner;
Important!
oRefrigerant circuit of air conditioner must not be opened.
oRefrigerant pipes Kink easi Iy .
... - Unscrew bracket -arros- for refrigerant hose at oi I sump.
10-16
... Unscrew and remove coolant pipe -3~.
Unscrew Aie compressor -arrows- and hang up on side.
Note:
Refrigerant ci rrut t can only be opened in workshops wi th s pee; a II y t ra i ned personne I and necessary tool s and workshop equipment.
- Detach wi re -2- from oi I temperature gauge sender.
Remove lower coolant hose -1- to radiator.
... - Remove front exhaust mani fol d:
Unscrew baits at bottom left and right -arrows-.
10-1/
-<II - Unscrew three bolts -'1- on corrugated pipe.
- Unscrew four nuts on turbocharqervsxhaust down pi pe fl ange -2-.
Note;
a To remove lower rear nuts -2- on turbocharger/exhaust down pi pe fl ange, fl at ri ng spanner SW 15 must be bent to fi t -arrow below in diagram-.
a Other nuts on turbocharger/exhaust dawn pipe flange are spanner size 17.
Take out exhaust down pipe downward •
... - Remove cover for right drive shaft -arrows- .
10-18
... - Unscrew nuts of left and r i qht engine mounts -arrow-.
- Unscrew bolts on engine/gearbox flange accessible from below .
... - RemDve traverse with torque arm. To do thi s , remove pressure reservoi r bracket from I eft long; tudi ria 1 member and torque arm from engine. Unscrew four bolts -arrows- and remove traverse.
10-19
... - Position gearbox support 10-222 A on wing. attachment 1 i p.
- Hook gearbox mount 3147 into upper right bolt hole of gearbox bell housing (in diagram shown with engine removed).
Note:
Height of gearbox can be adjusted with wing nut of support hook .
... - Hook engine support 2024 A to engine and to workshop Crane 1202.
Note:
In order to bal anee engine's centre of gravity, bar, for lifting hook, rust be fitted as shown in diagram.
Important!
Hooks and pins of engine support must be secured with safety cl tps -arrows in diaqram-.
10-20
... - Ensure suffi ci ent space between eng"i ne support and vacuum hose -arrow-, Remove hose if necessary.
L itt engi ne with workshop crane us: ng pins of engi ne mountings.
- Retighten wing nut an gearbox support 10-222 A accord: ngl y,
Upper engine/gearbox fl ange: Unscrew 1 ast bol t.
- Pull engi ne off gearbox and 1 i ft upward out of engi ne compartment.
Note'
Guide engine carefully when lifting out in order to evoi d damag i ng (1 utch, body and radi ator.
Vehicles with automatic gearbox:
- After remo~ing engine, secure torque converter in gearbox from fall i ng out.
10-21
SECURING ENGINE TO REPAI R STAND
.. Secure engine to repair stand with engine and gearbox bracket VW 540 in order to carry out repairs.
I'!ill..;.
Do not measure cylinder bores (Repair
Group 13) with engine mour ted on repair stand.
10-22
Install engine in reverse order and observe following points.
o (neck whether locating sleeves for centring engine/gearbox are installed in cylinder block; fit sleeves if necessary.
o Always renew self-locking nuts.
o Always renew seals.
c If necessary, check centring of clutch d ri ve pia te •
Q Clean toot~ing of gearbox tnput shaft.
Thinly coat toothing and cl utch release beari ng with G 000 100. Do not grease guide sleeve for release bearing.
a Make sure that support tab of cool ant pipe is not pi nched between engi ne and gearbox wh i I e pushi og these together.
a Install engine mounting torque-free by ali gni ng engi ne wi th shak i ng movenent.s before tightening engine mounting.
o Install coolant pipe, retaining clip for refri gerant pi pe and Ale compressor together.
10-23
o When ti ghteni ng exhaust down pi pe on turbocharger, ensure freedom of movement between exhaust down pi pe and subframe.
o Align exhaust system tension-free - Repair Group 26.
o Adjust throttle cable - see Repair Group 20.
a Do not reuse drained coolant. Fill coolant - see Repair Group 19.
a Check oil level before starting engine.
tIlill..;.
o Secure all cable ties taken out during removal at same location during installation.
a Secure wi ri ng exposed duri ng removal tension-free at same location during installation.
10-24
TlGHTENING TORqUES
Bolts/nuts - general
M6 )0 ~m
M8 20 Nm
M10 45 Nm M12 60 Nm
ExceQt i DOS'
Exhaust down pi pe to turbocherqer 30 Nm
Exhaust down pi pe to corrugated pi pe 25 Nm
f.xhaust down pipe to catalyst 25 Nm
Catalyst to gearbox support 25 Nm
Ale compressor to bracket 25 Nm
Torque converter to dri ve plate 60 Nm
Vi secus fan to carr-i er 20 Nm
10-25
-
16
[I3 -10931
13-1
4- 20 Nm
5- Hexagon fl "nge
11 0 for tuml nq engine by hand with
open-end spanner SW 32
6- Belt tensi oner
0 To slacken ribbed belt, swivel bel t
tensioner toward left vehicle side
wi th open-end spanner and secure
wi th pi n 3204
/- Belt ~ull~~ fQr h~draulie R~mg
8- 20 Nm
s- H~dra~ Ii" R~mR brack~t
10- 20 11m
11- H~draul j c pumR
0 For power s teeri n9
15 12- ZQJlm
13- AJ tem.tgr bracket
14- .45.Jjm
15- Alternator
16- li...llm 5 6 78 9
4
11
2
II"h
. 15
.-
.~
23
21 20 191817
22
4 5 6 7 8 9
23
22
21 20 191817
16
DISMANTLING AND ASSEMBLING BlGINE REMOVING AND INSTALLING RIBBED BELT lMR;.
Exploded view shows version without air condittoner.
1- f.o.!l
a "FRONT" marking on outer ring m~st point in direction of travel
2- Vi seoys c I "tch
o Swi ten-on temperature: 76 ± 4 O( Ambi ent temperature at vi secus clutch
o Checking - see Repai r Gro~p 19
o Removi ng - see "Removi ng ri bbed belt" - Page 13-4
o Tightening torque of viscous clutch -2- to bearing -17-: 20 Nm
o Reverse-threaded
3· Ri bbed be It
o Mark direction of travel before rernov i ng wi th chalk or felt pen and observe when i nsta 11 i ng
Cppos i te direction of travel on used belt I eads to its destructi on
13-2
17- Vj ~~QY> cl utcb bearing
o ·Check for ease of'movement
4 9 10 11 18- 20 Nm
1 19- Vibration da!lljl~r !jitb b~1t ~ull~y
o Fit t i ng on toothed be It pu 11 ey of
crankshaft only possible in one
position: holes offset
0 Removing and installing ribbed belt
2 ~ - Page 13-1
20- 2.5.JJm
-~"~ 21- Ceot[l!.l bolt
i I ,~ --. 12 o Tightening torque - see "Removing
., and i nsta 11 i ng vi brat i an damper"
(j~-.-;: Page 13-9
22- Belt nul tev
0 For vi scous c I uteh
I I 0 "VOR~E" m<!rki n9 points in direction
of vehicle travel
15
23- l!!__/jjj] 23
22
21 20 191817
16
113 -1 0931
13-3
Note:
Mark direction of travel of ribbed belt with eha I k or felt pen before removi ng and observe when install ing. Opposite di reetion of travel with used belt leads to its destruction.
- Removing lock carrier plate - see· Workshop Manua lAud i 100 "Genera I Body Repai rs" , Repai r Group 50
... - Unscrew vi secus fan (use spanner wrench 3212 to brace)
- Lay vi seous fan in fan frame.
- If necessary. unclip lower wiring 100m from ten frame.
- Unscrew fan frame from radi ator and pull out upward together wi th vi seous fan .
... - Slacken ribbed belt by swinging tensioner in direction of arrow and inserting pin 3204 into holes.
- Remove ri bbed be 1 t.
13-4
IoHd II i ng:
.... 0 Rout i og of ri bbed be I t on vehi c I €s l!i1.t!!!ll.i ai r conditi ooer .
.... 0 Routing of ribbed belt on vehicles ~ conditioner.
2
3
8
I I
15 14
4
5 67
13 12 11 10 9
13-5
REMOVING AND INSTALLING TOOTHED BELT
Il.ill..;_
o A I ways renew gas kets and sea ling ri ngs. c Removing and insta11ing cy l inder head -
see Repair Group 15
1- liiJl
2- Upper toothed belt guard
3- Toothed belt
o .Removing and installing, tensioning - Page 13-10
a Mark direction of travel of toothed belt before removing
Only tension toothed belt with engi ne £Q]jj
o Toothed be 1 t IIll!iLn.!l1 be ki n ked
4- 65 Nm
a Use brace 3036 to loosen and tighten
5- Camshaft sprocket
Removi ng and i nsta 11 i ng - see "Removi ng and j ns ta II i 09 toothed be.t" - Page 13-10
13-6
6- Idler pulley
:2 3 4 5 67 8 7- Tensioner
a Tension toothed belt - see
"Removing and installing toothed
belt" - Page 13-10
o Only tension toothed belt with
engine ~
8- Re~r tootbed b~ It gua r~
9- 1Q_Jjm
10- Q--ring
0 Renew
11- Coo I ant pump
o Check shaft for ease of movement
o Renew cool ant pump if damaged or
leaky
0 Removi ng and i nsta II i ng - see
Repa i r Group 19 .
12- Tooto~~ belt g~ll e~ for mlnkshaft
13- ZUm
14- LQ~er tooth~d belt gUorl!
15- TDC marki n9
16- .10 Nm
I I
2019 18 16 15 14 13 12 11 10 9
113-8851
13-7
17- ~gJ1__j)_iillex
2 3 4 5 67 8 0 ~atch fixing when mounting on
toothed belt pulley
a Removing and ir.stalling ri bbed belt
- Page 13-1
18- V i brat ion damRer
a Mount i n9 of vi bra t i an damper and
belt pulley on toothed belt pulley
of crankshaft only possible in one
position - holes offset
·0 Removing and installing - Fi g. I,
Page 13-9
19- 2..5..J!m
20- Centra I bo I t
a Tightening torque - see "Removing
and installing vibration damper" -
Fig.,I, Page 13-9 15 14
13 12 11 10 9
[If=}S5]
13-8
i
.. ,..-......1
.. Fig. 1 Removing and installing vibration damper·
o Ti ghteni ng torque !!.i.lb. spanner for vi brat i on damper 2079,
.lli...Hrn.
a Tightening torque without spanner for vi brati on damper 2079:
450 Nm
a Use brace 3256.
o Coat threads and contact surfaces of bol t head with sealing paste AMV 188001 02.
lM..e..;_
Spanner for vibration damper must align with torque wrench.
13-9
Remov i n9:
a Engine installed.
Note:
o Mark di rectian of travel of toothed belt wi th cha 1 k or felt pen before removi nq , a Toothed belt must not be kinked .
.. - Remove noise insulation -arrows-,
Disengage additional front retaining lug in centre of noise insulation.
- Remove front bumper - see Workshop Manual Audi 100 "General Body Repairs", Repair Group 63.
- Remove lock carrier plate - see Workshop Manua 1 Aud i 100 "Genera 1 Body Repai rs" • Repair Group 50 •
.. - Unscrew bracket for trim plate -2- from right vehicle side.
- Unscrew ri ght and 1 eft radiator bolts -3-.
Unscrew left air guide from radiator _]_. Remove upper air duct from radi ator.
13-10
<II " Attach support 3251 to ri ght bumper mount
and swing radiator forward.
<II _ Unscrew vi secus fan (use spanner wrench 3212 to brace) .
• Slacken ribbed belt and remove" Page 13-4. - Unscrew tensioner for ribbed belt.
- Remove upper toothed belt guard.
13-11
Note:
Instead of "0", notch can also be made in flywheel as TDC marking.
<II Turn crankshaft to TDe, cylinder L TOC marking must be positioned below edge in inspection hole ...
<II _ ••• and markings on camshaft sprocket and
cy Ii nder .head cover must ali gn,
If markings on camshaft are offset by half rotat i on, turn cran kshaft addi tiona 1 rotation.
Note:
Hexagon fl an.ge [SW 32) is provided on hydraul ic pump for turni ng engine by· hand.
13·12
fngi ne removed:
<II - Align notch on belt pulley with adjustment edge on oi I pump hous i ng.
1lill.l.
There is also an adjustment marking located on lower toothed belt guard (removed in diagram) - Page 13-7, item 15.
Cy 1 i nder head cover removed:
<II - Marki ng on camshaft s prcc ket must a Ii gn wi th upper edge of cy 1 i nder head.
13-13
<II - Loosen bolts of tensioner ·1 ... 3-.
- Remove vibration damper - Fig. 1, Page 13-9.
Remove lower toothed bel t guard.
- Take off toothed belt with vibration damper.
lnstalling:
<II - Lay toothed belt on belt pulley of crankshaft and secure vibration damper to crankshaft - Fig. 1, Page 13-9.
- At same time, fit lower toothed belt guard.
Note:
Toothed belt must not be pinched between oi 1 pump and toothed belt pulley when tightening vi brati on damper.
- Ti ghten lower toothed be It guard (10 Nm).
13-14
Note:
Instead of "0". notch can be made on flywheel as TDC marki ng .
.. - Check TOC position of crankshaft ....
.. - ... and camshaft agai n. Marki ngs must
al i gn.
Note:
Markings with cylinder head or engine removed - Page 13-13.
13-15
.. - Fit tcotned bel t via idler pulley and coo I ant pump or censha ft sprocket.
Tension toothed belt by turning tensioner toward right -arrow- with bolts -1 ... 3- loosened .
.. - It must be possible to just twist toothed belt by 90" in centre between camshaft sprocket and (001 ant pump with thumb and foref; nger.
- Tighten tensioner bolts to 20 Mm.
- Check basic adjustment of Hall sender - see
Workshop Manual Audi 100 "Motron; c Ignition and Injection System".
13-16
27 26 25 24 23 22 21 20 19
113-886
13-17
5- 1.Q..1lm
6 7 8 9 6- Beari ng ca~
o Bearing cap 1: Selt pulley end
o Retai ni ng I ugs on bear; ng shell s
must ali gn
a Watch bore offset
7- 65 Nm
8- TWQ-Qart fin/heel
0 Reduces rotational vi brat; on in
power trai n
o Removi ng and i nsta 11 i ng - Fi g. 7,
Page 13-24
o With welded-on lugs for ignition
firing point and firing angle
o Measure distance from lug to
ignition firing point sender {-G4}
and di stance from flywheel to
eng i ne speed sender [-G28}
Page 13-25
9- 30 Nm + 1[1 turn (90")
o Renew
10- ~eedle bggIiD9
o Lubri cate wi th MOS, grease
c Driving out - Fig. 5, Page 13-23
0 Driving in - Fig. 6, Page 13-23
10- ill Nm
1 r
27 26 25 24 23 22 21 20 19
113-886
13-18 8
6
7
9
I
D~ifl~NTL!NG:W ASSEMBLING CYLINDER BLOCK,
C SHAFT A FLYWHEEL.
Note:
o If metal shavings and abrasion in large quant it i es - caused by scori ng damage, such as pi ston, crankshaft or conrod bearing damage - are discovered in engine oil during engine repairs, crankcase and 0; 1 passages must be
ca refu 11 y cleaned in order to avo i d further damage. Oil cooler must be checked for shavi ngs and renewed if necessary - see Repai r Group 17. Servicing clutch -see Workshop Manual Audi 100 "5-Gear Manual Gearbox OIA 4- Wheel Drive". Repai r Group 30.
o Always renew seals.
1- Intake pipe gasket a Renew
2- Securing plate a Renew
4- Suction pipe
a Attach to oi I pump first
6
22 21 20 19
113-886
6
7
8
9
1 I
27 26 25
12-~
o Pressing out - Fi
o Pressing in _ F' g. 1, Page 13-21 1 g. 2, Page 13-21
13- Seal i ng fl ange
14- Gasket
a Renew
15- Crankshaft
o Measuring axial
Page 13-24 clearance - Fi g. 8
o Check radi I I '
PI ast 1 gage a ~ earance wi th
Crankshaft dlm:ge .13-28
16- ns 1 ons - Page 13-27
Thrust washer
o For cap
o Watch how secured
17- Bearing shell 4
o Wl th thrus t washers For cap wi thout '1
01 groove
18- Thrust washer
o For cap
o Watch how secured
19- Thrust washer
o ~or cyl i nder b lad
o tthout retaining lug
13-19
20- Bearing shell 4
o Wi th thrust was her
o For cylinder block with oil
21 groove
- Thrust washer
o ~or cyl i ndar block
o ithout retaining lug
22- Bearing shells 1 2
o For cap ~ ,3,5 and 6'
o For cylinder blo~~l groove
o Do not i nterch I'll th all groove
she 11 s ange worn beari n9
o Retalning lug must en .
of crankcase/bear' gage In recess
1 ng cap
23- Oi 1 pymp gasket
24- ~
o Watch cran ksh f .
i nsta 11 i ng pat dr i ve' when ump
25 - !lli...ill.l
o Pulling out - Fi
PreSSing in _ "g. 3, Page 13-22
26- 1 g. 4, Page 13-22
1QJJm
27 - 2.Q.JJm
13-20
<ill Ej g. 1
Pressing out 'ojl seal for crankshaft (tl vwheel end)
Removing and installing flywheel - Page 13-31.
- Press out oi 1 seal wi th nul l er hook 2086.
<ill Fig. 2
Press i n9 in oil seal for cremsnart Ifl vwhee I end)
Lightly oil sealing lip and outer edge of oil seal before installing.
Press in oil seal with installing tool 2003/1 as far as possible.
13-21
<ill Fig. 3 Pull ing out crankshaft oil seal (pulley end)
Remov i ng toothed be It - Page 13-] 0 Removi n9 vi brat i on damper - Page 13-9. - Pu II out oi I sea I with 0 i I sea I pull er 3203.
<ill Fig. 4 Pressing in crankshaft oi 1 seal (pull ey end)
Lightly oil sealing lip and outer edge of oil seal before installing.
Fit oil seal over installing sleeve from 2080 A.
- Press in oi 1 seal fl ush with 0; 1 pump housing using installing sleeve 2020 A (use securing bolt of Vibration damper).
Iii!J&.i.
If crankshaf't shows signs of scoring, press oi I seal l!.ooif_.
13-22
10-505
30-506b
... Fig. 5 Driving out needle bearjng
o Fl ywhee 1 removed
- Drive out bearing with 20 lm1 dia. drift from backside of flywheel.
<II Fig. 6 Driving in needle bearing
o Closed side of bearing points towards crankshaft.
- Oil outside of bearing housing.
- Dri ve in fl usn wi th fl ywhee 1 (clutch side)
with dri ft 10-505 and press i ng tool 30-506 b.
13-23
<II Fig. 7 Removing and instR1J.LM~
- Switch around brace 10-201 when i6stalling. o Tightening torque: 30 Nm + 1/4 turn (90'). Note:
Flywheel can only be fitted in one position - holes for securing bolts are offset.
<II Fig. 8 Measuring crankshaft axial clearance
- Measure axial clearance at No.4 bearing (thrust beari ng).
New: 0.07 ... 0.23 nm.
Wear limit: 0.30 nm.
13-24
._
MEASURING DISTANCE FROM LUG TO IGNITION FIRING POINT SENDER r-G4l AND DISTANCE fROM FLYWHEEL TO ENGINE SPEED SEN PER r-G28]
... 1, 2- Firing angle lugs (for ignition tester)
3- Ignition firing point lugs {for ignition firing point sender -G4} •
... - Turn flywheel until lug is positioned under opening of ignition firing paint sender.
13-25
- Screw in ignition firing point sender . ... - Insert feeler gauge between lug and ignition firing point sender.
Specified value: 0.45 ... 1.25 1l111 •
... - Insert feel er gauge between flywheel toothi ng and engi ne speed sender.
Specified value: 0.50 ... 1.25 mm.
13-26
CRANKS~AFT DIMENSIONS
(Di mens ions in 11111)
Hani ng Main bearing Crank
dimension journa I d i a. journal dia.
Basi c -0.022 -0.022
dimension 58.00 47.80
-0.042 -0. 042
1st -0.022 -0.022
undersi ze 57.75 47.55
-0.042 -0.042
2nd -0.022 -0. 022
undersi ze 57.50 47.30
-0.042 -0.042
3rd -0.022 -0.022
undersi ze 57.25 47.05
-0.042 -0.042 13-27
CHECKING CRANKSHAFT RADIAL CLEARANCE
o Check radial clearance with Plastigage. Note;
It is also possible to check radial clearance with engine installed.
Measuri ng range of Co lour Type
Plastigage strip
0.025 ... 0.076 11111 green PG- J
0.050 ... 0.150 11111 red PR-l
0.100 ... 0.230 rTI11 bl ue PB-l - Remove crankshaft bearing cap.
- CI ean bearing shell and crankshaft journal.
Place Plastigage strip corresponding to bearing width on journal or in bearing shell in axial direction.
- Install cap and shell and tighten to 65 Nm. Note'
Do not rotate crankshaft.
- Remove beari ng cap agai n.
... - Compare wi dth of PI asti gage stri p with measuri ng sea Ie.
New; 0.018 .•• 0.058 mm.
Wear limit; 0.16 mm.
13-28
6:&-1 ~~ 2
8---~
8---
I 13-721
13-nl
01 SMANTLI NG AND ASSEMBLING PI STONS AND CON RODS
I· Piston rings
a Offset gaps by 1200
a "TOP" marking paints toward piston crown • fi g, 5, Page 13·34
o Removing and installing - fig. 6, Page 13-34
o Checking side clearance - Fig. 7, Page 13-35
a Checki og ring gap - Fi~. 8, Page 13-35
2- Piston
o Mark installation position and cylinder number, Fig. I,
Page 13-32
a Checki ng - Fi g. 4, Page 13-33
o Removing and installing. Fig. 2, Page 13·32
o Arrow on pi stan crown poi nts towa rd pulley end
a Piston dimens tons - Page 13-37
3- Con rod
a Always renew as set
Mark cylinder number with punch ·AInstallation position: Markings ·Spoi nt toward pull ey end
13·29
4· Conrad bear; n9 cap
a Mark cyl i nder number wi th punch -A· D Installation position: Markings -B· poi nt toward pull ey end
5· 30 ~m + 1/4 turn (90'J
o Only renew when engine is completely dismantled
o Oi 1 contact surfaces
o To measure radial clearance, tighten to 30 Nm, but no further
6· ill£l.io.
o Lever out • Fi 9. 3, Page 13·33
7- PistDn pin
o Remove and i nst.al ' wi th drift 10·508
c If difficult to remove, heat piston to approx, 50 'c
8· Con rod bo It
o Only renew when engi ne is camp 1 ete I y di smant led
.9· Cylinder block
o Checking cylinder bores > Fig. 9, Page 13-36
o Piston and cylinder dimensions - Page 13-37
13-30
10- Beari ng shell
a Note installation position
a Do not interchange used bea ri ng shell s
a Observe marking (original dimensi onsl overs i zc)
a Retaining lugs must engage in recesses in beari og caps and can rod
o Measuring axial clearance - Fig. 10, Page 13-36
o Checking radial clearance with Plastigage - Page 13-38
11- Oi I spray jet
o For cooling piston
12- lJl.J!!!l
o Install with locking compound D6
13-31
... ~1 Marking piston installation RQsition
a A rrow on piston crown poi nts toward pull ey end. Mark cyl i nder number -1 to 5-.
a Clearly mark sequence on piston crown with waterproof f€lt pen.
Important!
Do not use punch, as piston :r'Jwn is coated.
... Fi g. 2 Removi n9 and install i n9 pi stan
o I nsta 11 wi th pi stan ri ng compressor.
13-32
... Fig. 3 Levering oyt "circlip
<III fig. 4 Checkjng piston
o Measure approx. 10 11111 from bottom of ski rt and 90' offset to piston pin axis.
a Maximum deviation fram specified dimension:
max. 0.04 11111.
13-33
... Fig. 5 Installation position of Riston rings
a "TOP" must face toward pjston crown.
o Chamfer On plane ring must face toward pi ston crown.
o Step on stepped ri n9 must face toward piston pin.
<III Fi 9. 6 Removi n9 and j ns ta II i n9 pi stan rj ngs
a Remove and i ns ta II with pi stan ri ng pi i ers.
13-34
I I 2
/_.~+-- -, I
... Fig. 7 Checking piston ring side clearance in groove
- Cl ean ri ng groove before ehec ki ng.
New: 0.04 ... 0.072 ITITI.
Wear limit: 0.1 l11li •
... Fig. 8 Checking piston ring gap
- Push ring squarely into Jower end of
cyJ i nder until it is approx. 15 nm from cyJ i nder edge.
New: 0.15 0.35 nrn.
Wear limit: 1.0 rrrn.
13-35
... Ii&.. 9 Checki n_g__£i}j_IJder bares
- Measure bores at 3 locations diagonally across engine -A- and longitudinally -B-.
a Use internal dial gauge, 50 ... 100 mm.
a Deviation from nominal dimension: max. 0.08 11111.
(Piston and cyl inder dimensions - Page 13-37)
Note:
Cyl i nder bores must not be measured when cylinder block is mounted on repair stand with adapter VW 540 -Repair Group 10-, as incorrect measurements are then possible.
... Fig. 10 Measuring conrod axial clearance
a Wear limit: 0.411111.
13-36
PISTON AND CYLINDER DIMENSIONS
(Dimensions in ITITT)
Honi ng Pi stan Cyl. bore
dimensi on di a. dts ,
Bas i c 80.98 81. 01
dimension
1st oversize 81. 23 81. 26
2nd overs i ze 8l.48 81. 51 13-37
CHECKING CONROD RADIAL CLEARANCE
a Check radial clearance with Plastigage.
Note:
TtTS also possible to chec]; radial clearance wi th engi ne i nsta 11 ed.
Measu ri ng range of Colour Type
Plastlgage strip
O. 025 •• , Q. 076 11111 green PG-l
0_050 .•• 0.15011111 red PR-l
0.100 .,. 0.230 rrm blue PB-1 Remove conrad bearing cap.
Clean bearing shell and crank journal.
... lay Plastigage strip corresponding to width of crankshaft journal in axial direction journal or in bearing Shell.
Install conrad bearing cap with bearing shell and tighten to 30 Nm, but no further.
~
Do not rotate crankshef't ,
- Remoye conrad bearing cap again •
... - Compare width of Plastigage strip with measuring scale.
Conrad radial clearance:
New: 0.010 •.. 0.05 11111.
Wear limit: 0.1~ 11111.
13-38
CHECKING BASIC MECHANICAL ADJUSTMENT OF ENGINE
o Toothed belt tension OK - Page 13-16.
- Remove upper toothed belt guard.
Note:
o Hexagon fl ange (SW 32) is provi ded on hydraulic pump for turning engine by hand.
o Instead of "0", notch may also be made on flywheel as TDC marking.
<II - Turn crankshaft to TOC, cyl inder!. TOe marking must be positioned below edge in inspection hole ...
<II - ••• and marki ng on camshaft sprocket and cylinder head cover align.
Note:
a If markings on camshaft are offset by 1/2 turn, turn crankshaft one additional turn.
o If markings do not align, toothed belt has Jumped. Adj ust i ng - see "Removi n9 and
i nsta 11 i ng toothed belt" - Page 13-10 and check bas i c sett i ng of Ha 11 sender - Workshop Manual Audi 100 "Motronic Ignition and Injection System".
13-39
4------- 3-------
2------
1-----~
4---------
3----~
2-------
1----
115 -793 1
REMOYING AND INSTALLING CYLINDER HEAD
Hll1e ,
o cy:l i nder head Can be removed and installed with engine installed.
o Removing and installing toothed belt - see Repair Group 13.
o Removing and installing injectors - see Workshop Manual Audi 100 "Motronic Injection and Ignition System".
o Cyl i nder heads wi th cracks between valve seats or between va I ve seat insert and spark plug threads may be reused without reduc i ng serv ice life. provi ded era c ks do not exceed max. 0.5 nm in width, or when no more than fi rst spark plug threads are cracked.
a When installing replacement cylinder head wi th fitted camshaft. contact surfaces between bucket tappets and cam surfaces must be Oiled after install ing cyl i nder head.
o When renewing cyl i nder head or cylinder head gas ket, renew all coo I ant.
o Checking compressi on - Page 15-7.
15-1
1- Cylinder head gasket a Renew
a Ensure correct installation position: "OBEN" marking or part number must face cyl i nder head
a Fi t gasket aver centri n9 pi ns in cyl i nder block
2- 20 Nm
3- G.likt
o Renew
4- eyl j nder head
o Checking for distortion - Fig. l ,
Page 15-5
o Refi ni shi ng - Fi g. 2, Page 15-5
o Installing - Page 15-6
o Ser~icing valve train - Page 15-9
5- 65 Nm
6- [yl i nder head bal ts Renew
Follow installation instructions and sequence when 1 ooseni ng and ti ghteni ng - Page 15-6
7- Heat shield
8- QLJjm
15-2
25
7 6 5 ~i$-
4 --~-- .i--:
3 .
~I ~ -
~- _-_ - ~,. '~~ ~~~--'---'~ ;;;---iF --~~~
~~d~---_--
,~~ ,w,;:__
.Y v~~ 28
r 29
30
9- 10 Nm
a Ti ghten d i agona 11 y
10- Gas ket
a Fl anged surfa
manifold ce must face exhaust
11- .2_5___!jm
a Renew
12- E h
x aust mani fo 1 d
o W,th turbochsrcer
13- 10 Nm
14- Spri n9 with bracket 15- 10 Nm
16- Cover
o With - .-
19mtlOn coils
1 7 - .!ilil\tl
a Only renew if
1 nsert _ damaged
l n groove .
lB j n cover
• (eliminated)
19- 10 Nm
to- 10 Nm
15-3
21- Bracket
a For vacuum hoses
22- Cyli nder head
cover
23- G k
odS et for cylinder
-On 1 y renew if d head cover
a Insert in amaged
cover groove on cyl i nder head
24· p~
o Only renew if d amaged
25- Intake manifold
o Use All en socket
remove and - V.A.G 1669 t
Install a
2£-Bolt
OFOr oil dipst
o 10 Nm 1 ck gui de tube
27- G.illlll
o Renew
28- O-ring
o Renew
29- Coolant - plpe
30- J.jJ__Jjm
15-4
E!'
9
5
7
11
3
12
8
6 10 115-7601
2
4
<II Fig. 1 Checking cylinder head for distortion
- Measure with feeler gauge at several locations.
Distortion: max. 0.1 mm.
<II Fig. 2 Refinishing cylinder head
o Refinishing cylinder head (grinding flat) is permissible up to minimum dimension
a = 118.1 mm (measured through bolt hole).
15-5
INSTALLING CYLINDER HEAD
Note:
o Renew cyl inder head bolts.
o There must be no oil or coolant in blind holes of cylinder head bolts in cylinder block.
- Before fi tt i ng cyl i nder head, set crankshaft and camshaft in cyl i nder head to TDC cyl i nder 1.
- Fit cyl i nder head gas ket over cent ri ng pins: "OBEN" or part number must face cyl inder head (watch hole pattern).
- Install cylinder head fit cylinder head bo 1 ts and tighten by hand.
<II - Tighten cylinder head bolts in total of
three stages - for sequence, see diagram.
- Ti ghteni ng torques (engi ne cold):
a Stage I = 40 Nm
o Stage II = 60 Nm
a Stage III 1/2 turn 1180°) further with ri gi d spanner wi thout stopping (2 x 90° is also permissible) .
Note:
o Loosen cyl i nder head bolts in reverse order.
o Additional retightening of bolts is not requi red.
15-6
CHECKING COMPRESSION PRESSURE
o Engine warm (Coolant temperature gauge at aoprox. 80°C) .
... - Turn Gil i ck fasteners -arrows- on connector cove, on rear engine compartment bulkhead 90" to I eft and remove caver.
... - Mark and separate connectcrs -5- and -6- (to ignition coils).
Remove cover with coi 1 s on cyl i nder head cover - Page 15-3.
- Unscrew ill spark plugs with spark plug spanner 3122 A.
15-7
Check compression pressure with compression pressure recorder V.A.G 1381 and adapter 1381/1.
o Thrott 1 e va lve fully open.
- Operate .s tar ter unt i I no further pressure increase is indicated by tester.
('ompressi on pressures (i n bar)
Specified value Wear limit
o Max. permissible pressure difference between
i ndi vi dua 1 cyl i nders
o 9.0 ... 13.0 U.
15-8
5 2-
6 3-
7
8 4-
9 5-
6-
10
11
@:7S~ 11----
SERVICING VALVE GEAR
Note:
Cyl inder heads wi th cracks between val ve seats or between valve seat inserts and spark plug threads may still be used
wi thout reduci ng serv i ce I He, provi ded cracks do not exceed max. a.5 mm in width, or when no more than first spark plug threads are cracked.
1- Beari ng cap
a Observe·i nstallation posi tion and numbering - Fig. 1 and 2,
Page 15-12
a Installation sequence - see
"Removi n9 and i nsta 11 i ng camshafts' - Page 15-21
lillrn
Oi I seal
o Renew - Page 15-18
Drive chai n
Outer val ye spri ng
o Removing and installing - see item 14
Inner val ve ,pri ng
o Removing and install ing - see item 14
15-9
)- Lower val ye-spri ng seat
a Removing and installing - SEe item 14
o Possible to take off after removing va 1 ve stem seal - Page 15-29 or 15-31
8- Valve stem seal
o Renewi ng with cyllnder head installed - Page 15-29
o Renewi ng wi th cyl i nder head removed - Page 15-31
9- ValVe guide
o Checking. Fig. 5, Page 15-15
o Renewi ng . Page 15-27
10- Cyl i nder head
a Installing - Page 15-6
a Reworking valve seats - Page 15-24
o Checking .for distortion, reworking - Page 15-5
11- W:iei
o Only grind in, do not rework
o Valve dimensions - Fig. 4, Page 15-14
o Exhaust valves sodi um- fi II ed, follow ins t ruet ions on scrappi ng - Page 15-14
15-10
12- Camshafts
a After installing camshafts, do not start engine for approx. 30 minutes (valves strike pistons), then turn crankshaft 2 rotations
o Checking axial clearance (bucket tappets removed) - Fig. 3,
Page 15-13
o Removi ng and 1 nste 11 i ng - Page 15-20
o Check radial clearance with Plastigage (bucket tappets removed)
13- Bucket tappet (hydraulic)
o After installing bucket tappets, QQ not start engine for
apRrox. 30 mjnutes (valves strike pi stons), then turn crankshaft
2 rotations
o Oi I runni n9 surfaces
Do not interchange (mark)
When rernovi ng, set as i de tappet with running surface facing downward
D Checki ng - Page 15-15
14- Val ve wtters
o Removing and installing:
- With cylinder head installed, with valve fitting tool 2036 and valve lever VW 541/1 - see "Renewi og va I ve stem sea Is" - Page 15-29
- With cylinder head removed - Page 15-31
15- Upper valve-spring seat
a Removing and installing - see item 14
15-11
.. fig. I Installation position of camshaft beari 09 cap
a Recesses at corners of beari n9 caps must point toward intake side of cylinder head -arrow-.
o Install beari ng caps accordi ng to numberi ng I to 10 on caps as shown in diagram .
.. Fig. 2 Installation position of camsha ft beari 09 caps
o Watch offset. Before i nsta 11 i n9 camshaft, fit beari ng caps and determi ne installation position.
15-12
1----- C ------<~
... .Fig. 3 Checking camshaft axial play
Remove bucket tappets.
Camshaft wi th fi rst and illl beari ng cap fitted.
o Cha in removed.
- Screw universal measuring gauge bracket VW 387 onto face of cylinder head and insert gauge.
o Axial clearance; Wear limit: 0.2 mm.
15-13
... Fig. 4 Valve djmensions
Inlet valye
Exhaust ya I ve
a ' 32.00 mm d a. b > 6.97 mm d a. c = 95.50 mm d a. r.r = 45°
a = 28.00 mm dia. b = 6.94 mm dia. c ' 98.20 mm did. r.r ' 45·
Note:
Valves may not be reworked. Only grinding in is permissible.
llll~ortant!
Worn-out sodium-filled exhaust valves cannot simply be scrapped. Using hack saw,
. valves should be cut tn two across middle of stem. During this operation, they must not come into contact wi th water. Throw maximum of ten valves prepared in this way into bucket of water and step back quickly to avoid any danger from ensuing chemical react ion, duri ng whi ch sod i um wi 11 burn. Parts treated in this way can then be disposed of with other scrap.
15-14
... fig. 5 Checking valve guide
- Screw universal measuring gauge bracket 'VW 387 onto sea ling surface of cy l i nder head and insert gauge.
- Insert new valve into guide. Valve stem
end must seal with guide.
Note:
Due to differing stem diameters, only insert inlet valve into inlet guide and exhaust valve into exhaust qui de.
'@l:!.L rac k:
Wear limit: Inlet valve guide 1.0 nm,
Exhaust valve gui de = 1. 3 fIlTl.
15-15
CHECK] NG HYDRAULIC BUCKET TAPPETS
Importantl
After installing new or reinstalling Did bucket tappets, and after ins ta II i ng camshafts, engine must not be. started for appro •. 30 minutes. Otherwise valves
st n ke pi st ons ,
After this period, ~arefully turn cranksha ft two rotations by hand in order to ensure that no valves strike pistons.
Note:
o Brief valve noise during starting is norma I .
Do not interchange bucket tappets (mark). Set as; de removed tappets on cl ean surface with running surface [cam side) facing downward.
o Defective bucket tappets must be renewed (repairs are not possible).
15-16
Run eng i ne until opera t 1 ng tempera tu re is reached (cool ant temperature gauge at approx. 80 °C).
- Increase engi ne speed to approx. 2500 rpm for 2.minutes.
If tappets are still noisy, locate defective tappet as follows:
Remove cy l i nder head cover.
- Rotate crankshaft clockwise unt: I cam of tappet to be checked is pointing upward.
<III - Press aown tappet wi th wooden or pia sti c
wedge. If free travel in excess of 0.1 ITIl1 is felt, renew tappet.
15-17
RENEWING CAMSHAFT OIL SEAL
~
Remove upper toothed-belt guard.
<III Rotate crankshaft until No.1 cylinder is at TOC.
- Slacken toothed belt and remove.
- Remove camshaft sprocket.
- Screw camshaft-sprocket securi ng bolt wi th
washer into camshaft as far as possible.
- Unscrew inner sect; on of oi I sea 1 extractor 2085 two turns (approx. 3 nm) out of outer section and lock in position with knurled screw.
<III - Oil threaded head of oil seal extractor,
place in position and screw into oil seal as far as possible while exerting firm pressure.
15-18
- Loosen knurled screw and turn inner part of ext ractor again, t cemsha ft until oi I sea I
is extracted.
Clamo extr-actor in vice on flats and remove oil seal with pliers.
1 nsta 11 i n9:
Lightly oil seal ing lip and outer edge of oil seal.
- Push oj I sea I onto i nsta 11 i ng s I €eve from 10- 203.
- Press oil seal home with installing tool 10-203 and offset bolt 10-203/1.
Note:
Do not pres S oi I sea lover fi r s t 5 hou I der, otherwi se oi I return hole wi 11 be covered.
15-19
FEMOVING ANP INSTALLING CAMSHAFTS
Removi ng:
- Remove upper toothed-belt guard.
Ii2l..e_t
Instead of "0", notch can al so be made on flywheel as TDC marki ng .
... - Rotate crankshaft until No.1 cylinder is at TDe. TDe marking must be located under edge in inspection hole ...
... - ... and marki ngs on camshaft and cyl i nder head cover must align.
- If marki ngs on camshaft are 112 turn offset, turn crankshaft one additional rotation.
Note:
Hexagon fl enge (SW 32) is pravi ded on hydraulic pump for turning engine by hand.
15-20
\
... Loosen tensioner bolts -J ... 3-.
- Remove csmshaf't sprocket.
- Remove cy Ii nder head cover.
Exhaust camshaft:
... Remove bearing cap in front of chain, as well as caps 2 and 4.
- Remove beari ng cap I, 3 and 5 a I ternately in di agona I sequence.
Inlet camshaft:
Remove bearing cap in frant of chain, as well as 7 and 9.
- Remove beari n9 caps 6, 8 and 10 a I ternate I y in di agona I sequence.
15-21
Instal J j ng:
- Oi I all runni n9 surfaces .
... - Fit camshafts with chain so that markings on chain sprockets align -arrows- .
.Nill..;_
o When installing camshafts, Hall sender housing must be removed.
o For i nsta 11 i ng Hall sender housi ng and
bas i c set t i"9 of Ha 11 sender - see Workshop Manual Audi 100 "Motronic Ignition and Inject i on System".
o When ins ta II i ng bea ri ngcaps. ensure that recesses on corners of caps poi nt toward inlet side of cylinder head - Page 15-12.
Inlet camshaft:
... - Tighten bearing caps 6, 8 and 10 alternately in diagonal sequence. Tightening torque: 15 Nm.
Fit remaining bearing caps. Tightening torque: 15 Nm.
15-22
Exhaust camshaft:
<II - Tighten bearing caps I, 3 and 5 alternately in di agona I .seque-ce.
Tightening torque: 15 Nm.
- Fit remaining bearing caps.
Tightening torque: li.lI!!!.
Renew camshaft oi I sea Is - Page 15-18.
- Fit camshaft sprocket and tighten.
Tightening torque: 55 Nm.
- Install toothed belt - see Repair Group 13.
Important!
After installing new or reinstalling old bucket tappets, and after i nsta 11 i og camshafts, engine must not be started for approx. 30 mj nutes. Otherwi se Va 1 ves strike pistons.
After this period, carefully turn crankshaft two rotations by hand in order to ensure that no va 1 ves stri ke pi stons.
15-23
REWORKING VALVE SEATS
Note:
When servi ci n9 eng i nes with I eaky va I ves, it is not sufficient to rework or renew valve seats and valves. It is also necessary to check valve guides for wear - Page 15-15. This is particularly important when checking engine with high mileage.
On1 y rework valve seats enough to produce perfect contact surface. Sefore reworki ng ccmences , cal cui ate maximum Dermjssjble reworking dimension.
If this dimension is exceeded, correct functioning of hydraulic tappet can no longer be guaranteed and cyl i nder head must be renewed.
15-24
-
Calculating maxim~m permissible reworki.!!S dimension
... 0 Maximum permissible reworkin9 dimension is di fference between di stance -arrowmeasured at cylinder head and specified
mi nimum dimensi on.
Minimum dimension: at inlet valve: l6.....Q...mm
at exhaust valve: ~
Measuring distance -arrow-:
Insert val VI' into valve guide and press firmly against valve seat.
Measere di stance -arrow- between valve stem end and upper edge of cyl i nder head.
lli!IJill_;_
Distance:
minus minimum dimension:
37.0 nm 36.3 nm
= max, perm. reworking dim.
0.7 nlT1
15-25
... Reworking inlet valve seat
31.2 mm dia. (not gi ven)
c = 1.5 •.. 1.8 mm
If necessary, rework valve seat wi th 75' reseati ng tool
C = Lower edge of cyl i nder head 30°= Upper correct i on ang I e
45'= Valve seat angle
... Reworking exhayst valve seat
a 27.6mm dia.
b = (not given)
c = approx. 1.8 mm
C = Lower edge of cyl j nder head 30°= Upper correction angle
45"= Valve seat angle
15-26
•
3121
•
RENEWING VALVE GUIDES
~
o Only renew valve guides on cylinder heads on which permissible reworking dimensi~n of valve seat inserts is at least 0.5 nvn. Checking ~ Page 15·25.
o If this reworking dimension is Exceeded, cyl i nder head must be renewed •
.. ~ Press worn valve guides out from ~ chamber siue using 3121, using sleeve 30·23 as support.
15·27
.. • Moisten new guides with oil and press into cold cylinder head from camshaft side with 3121 until shoulder makes contact.
Note:
o Use support 3123 for pressi n9 in inlet valve guides.
o After shoulder on guide makes contact, pressure must not exceed 1.0 tomes, otherwi se shoul der may break off.
Ream out guides with hand reamer 3120, using cutting water.
Reworki ng val ve seats - Page 15·,4.
l!!l1!:.;,
When reworki n9 valve seats, observe permissible reworking dim€nsion - Page 15-25.
15·28
RENEWING VALVE-STEM OIL SEALS (With cyl i nder head i nsta 11 €d)
- Remove camshafts and bucket tappets - Page 15-20.
Remove spark plugs with spark plug spinner 3122 A.
Set piston of respective cylinder to BDC. - Screw compressed air hose VW 653/3 into spark plug thread and apply continuous pressure of at least 6 bar.
Inlet side:
... Bo It fi tt i ng too I 2036 to cyl i nder head and adjust to height of studs.
- Remove va I v€ spri ngs wi th va I ve I ever VW 541/1 and pressing piece VW 541/5.
Exhaust side:
- Remove va he spri ngs in same manner as described for inlet side.
Note:
... Ti ght cotters can be loosened by tappi n9 l_j_gb_U_y on I eyer VW 541/1 with hammer.
15-29
Remove valve. stem seals with puller 30V A •
... - Fit plastiC sleeve -A- onto valve stem.
Oil valve stem seal -B-, insert into fitting tool 3129 and push down carefully onto val ve guide.
~ote:
To prevent damaging valve stem seal, always use plastic sleeve (included with valve stem sea Is) .
15-30
RENEWING VALVE-STEM OIL SEALS (Wi th cyl inder head removed)
- Remove camshafts and bucket tappets - Page 15-20.
- Unscrew spa rk plugs wi th spark pluq spanner 3122 A.
Inlet side:
<ill Bolt fitting tool 2036 to cylinder head and adjust tohei ght of studs.
- Remove va I ve spri ~g 5 wi th va I ve I ever VW 541/1 and pressing piece VW 541/5.
Note:
Loosen tight valve cotters by li9.h.tlY tapping lever VW 541/1 with harrmer.
Exhaust side:
<ill Remove va I ve spri ngs wi th va he spri ng compressor 2037.
15-3;
- Remove valve stem seals wah puller 3047 A.
<ill _ Fit plastic sleeve -A- onto valve stem.
Oil valve stem seal -B-, insert into fitting tool 3129 and push down carefully onto val ve guide.
Note:
To prevent damaging valve stem seal, always use plastic sleeve (included with valve stem seal s).
15-32
117-303 i,
17-1
3- Qil Jl1'gssure rel i ef va he
o Meosu.ring oil pressure - Page 17-9
Threaded plug with sender for -ot l
temperature gauge: 30 Nm
13 0 Check: ng o i 1 temperature gauge
sender - Workshop Manual Audi 100.
"El cctr i ca 1 System"
4- 1Ulm
5- 1Q MID fQr 1'16
20 Nm for Mf,
14 0 When installing oil sump, tighten
di agonally in two stages
6- 1.O..l!m
15 7- S~~~[i 09 ~ 1 ~te
16 0 Renew
17 8- Gas ket
18 0 Renew
0 Do not band
19
20 9- 10 Nm
21 10- Qi 1 Rum~ gasket
a Renew
,., . 11- ~
.. ',f,
a Renew
4- ~~r-;---T-15
Ad-J.'--cc---1---+i--16 .1lIU);"iT"'-~-17 ·P((.;~~-18 __....-j;:..::..,~--19 f---20
_;;----21
22
117- 3031
REMOVING AND INSTALLING LUBRICATlON SYSTEM COMPONENTS
14
~
o Lubri cati ng system cnmponents shown in diagram can be removed and installed with engine installed.
a I f meta I shavi ngs and abrasi on in large quanti ties - caused by scari ng damage, such as piston, crankshaft or conrod beari ng damage - are discovered in engine oil during engine repairs, crankcase and 04 I passages most be caref'u l ly cleaned in order to avotd
fu rther damage. Oi I cooler mu s t be checked for snavi ngs and renewed if necessary - Page 17-7, item 27.
o Oi 1 spray jet for pi ston coo 14 ng - Page 13-31. Install bolt witll locking compound D5 and ti ghten to l!l..l!!n.
o Oi I ci rcuit capaci ty (with oi I fi lter): 4.5.1itres.
1-
Oil sea I
a Renew - see Repai r Group 13
2-
17-2
~23
e- 24
12-~
o Removi ng and .
Page 17-14 lnstalling-
o On I y renew en t i .
Ire unt t
3- .C..oQ
o Renew seal if d
14- . amaged
OIl dipstick
o Quantity diff
Ml n erence
15- . . ... max.: LD Itr.
~116 ~~tentiQn valve
o Remove and .
square All Install with 8
o Install en key socket om four-
WI th lock in spanner
16- ~er 9 compound 06
a SONm
11- 1.8 bar oi I
a 25 Nm pressyre swi tch ( .
a Check. _whltel
lng - Page 17-8
18- Oi I press
o 25 Nm ure sender...J."hlQl
o Check; ng - P
19- age 17-10
Suet i on pi pe
o Attach to .
o i l pump fi rst
17-3
20- lQ..Jill]
21- Baffle plate 22- ~
o Removi ng and .
Page 17-12 lnstalling-
o Cl ean sea lin "
mounting 9 surf'ece before
23-~
o Renew
24- N....!illl
17-4
28 27
23
1- !Q..Jim
2- Supply pipe
a For oi I cooler
3- Return pi pe
o For oi 1 cooler
4- !I.!l..llm
5- Adapter
o SO Nm
5- lll...Jim
7 - l!.liill
a Renew
8- OJ J thernostat
o For oil cooler
9 - .G.a.sill
a Renew
10- lQJim 11-~
o Renew
12- ~ c Renew
13- 1.Q_Jjm
14- ~i IF suWI V Qi pe
or turbocharger
15- liilltl
o Renew
16- Oi 1 retyrn pi oe
o For t b "
ur ocharger
17- 2.iJJm
18- l..Q___Ijm
19- Gas ket
o Renew
20- Oi J fi lte
o Wi th rt brae ket
t ange for "I
urbocharger 01 pipe to
a In~tallation ""
a I, gnment "pas It Ion is f"
p' ns i xed with
21- Oi I til tee
o Tightening tor
Loosen and t" que: 2..Q__fjffi
wrench ' ghten with st
o Lightl " rap
o Fi 11 y all seal OIl to n
engine ormal level ad
o Check f n start
necessaOryf lea ks and r t t
e 1 ghten it
17-6
22- Ba~jo bolt
14 0 70 Nm
0 Wi th O-ri ng
23- Ai r duct
21- Sel f-taRgi ng screw
0 For securi ng air duct
25- l.Q.J:Im
26- Qj I coo I er brae let
27- Oil coo I er
0 In case of engine damage, e.g.
piston, crankshaft or conrad
beari ng damaged, check for metal
2 3 shavi ngs and renew if necessary -
see note on Page 17-1
28- O-ri n9
0 Renew 28 27
23
117-302 1
17-7
CHECKING OIL PRESSURE SWITCH AND OIL PRESSURE
Test conditions;
o Oil level OK
o Engi ne oi I temperature at least 80°C
o Auto Check System OK (call up symbols)
!llite_;_
Checking and servicing Auto Check System - see Workshop Manual Audi 100 "Eleetri cal System".
Checking 1.8 bar oil pressure switch: (whi te i nsui ati on)
... - Remove oi I pressure switch -2- and screw into oi I pressure tester V.A.G 1342.
- Screw threaded connection -3- of oil pressure tester into cy 1 i nder b I ock in place of oil pressure switch.
- Connect brown wire -1- of tester to earth.
- Cornect di ode test lamp V.A.G 1527 to battery pes i t i ve (+) and to oi 1 pressure switch j n tester with auxil i ary wi res from
V.A.G 1594 A. '
o Oi ode test 1 amp must not light up, otherwi se renew oi 1 pressure switch.
-.: Start engine and slowly increase speed.
o At 1.&___,_,_,__2.0 bar: diode test lamp must lighj;_gp, otherwise renew 1.8 bar oil pressure swi tch.
7-8
Checking oil pre_s-"_uJ.:.\:..i_
Further jHC"'eJSe engine sp~£d.
a At 2000 rpm and oi 1 temperature of 80 "e, oil pressure must be at least 2.0 bar.
- Further increase engine speed.
Opening pressure of pressure relief valve: 3.0 ..• 4.5 bar.
This pressure may be only minimally exceeded _
Note:
ITOil pressure is excess t v€ (pressure re l i ef valve sticking or incorrectly installed), hydraulic tappets will be subjected to excessive pressure. Engine will cut out soon after starting and turn over noti ceably fast during subsequent starting due to lack of compression.
CHECKING OIL PRESSURE SENm;~. l_::' _'4-
Test conditions: o Oil level OK
a Engine oil temperature at least 80 O( o Auto Check System OK (call up symbols)
Note:
o Checki ng and servt ci ng Auto Check System - see Workshop Manual Audi 100 "Electrical System" •
o Installation position of oil pressure sender (-Gl0) - Page 17-3, item 18.
-4 - Pu 11 wi re off contact G of oi I pressure sender (-GI0).
- Connect hand multimeter V.A.G 1526 to ~ of oi I pressure sender and engi ne earth with auxiliary wire from V.A.g 1594.
- Set V.A.G 1526 to 200 0 measuring range (engi ne swi tched off).
Specified value: 5 ... 100 - Start engine and run at idle.
Specified value: 70 ... 120 n - Increase engine speed to 3000 rpm.
Specified value: 170 ••• 200 0
17-10
... ~ Pull off wi re from contact WK of ot 1 pressure sender (-GIO).
Connect hand multimeter V.A.G 1526 to contact WK of oi 1 pressure sender and engine earth with auxiliary wire from V.A.G 1594.
- Run engine at idle.
Specified villue: "n - Switch off engine.
Specified value: 0 ... 0.50
. If specified values are not obtained, renew oil pressure sender (-GIG).
t!Qk.;_
If wi res of oi 1 pressure sender are . incorrectly connected, warning symbol (oi 1 can) for engine oi 1 pressure appears in Auto Check System.
17-11
REMOVING AND INSTALLING all SUMP
Remoy; nq;
- Pullout oil dipstick •
... - Unscrew retaining clips -arrovs-.
- Unscrew wiring guide -1-.
- Unscrew two front bolts of subframe -2-.
Important!
When two front bolts of subframe are unscrewed, subframe drops down approx. 10 em,
Drain englne oil.
- 'There are two cutouts on flywheel cover and on f1 ywhee 1.
<III _ Turn crankshaft until two securlng bo l ts
-srrows- of oil" sump are visible.
- Remove oil sump.
17-12
lnsta 11 i ng:
• Re~€w gaskets,
Renew sub frame bo Its.
Tightening torque: 110 Nm + .11.4 turn (90").
17·13
REMOVING AND INSTALLING OIL PUMP
Removi ng:
· Remove toothed bel t > see Repai r Group 13.
· Remove oil sunp > Page 17·12. ... • Remove suet i on pi pe.
· Unscrew oi I pump and pull off crankshaft stub.
Instal I j ng:
· Renew gaskets.
· Fit sleeve from oil seal puller 2080 A to crankshaft journal to protect oi I pump sea 1.
· When installing oil pump, make sure crankshaft drive gear engages.
· Install toothed belt· see Repair Group 13.
17· 14
19-1
16 6- Fan wi th vi secus clutch
0 "FRONT" marki ng on outer fan ri n9
17 must poi nt in di recti on of travel
18 Switchi ng temperature 76 ± 4 °C
Ambi ent temperature at vi seDUS
cl utch
o Checking - Page 19-15
19 Removi ng - see "Removi ng ri bbed
belt" • Repair Group 13
a Ti ghteni ng torque of vi scous clutch
to bear; n9: 20 Nm
o Reverse threaded
20 7· Fan frame
21 B- 10 Nm
22 9- ThermQ~wi t~h fgr fao -E1B cr ·F54
a 25 Nm
23 a Switchi ng temperatures:
1 = lst stage on 92 • 97°C
24 off 84 . 91°C
2S 2 = 2nd stage on 99 • 105°C
off 91 - 98 O(
+ = Supply
io- la Nm
11- llitinS
12- Bonded rybber bu.b
13- Left ai r guide .. ·~----~16
{-----17
$-~1__---18
1------19
13
____:'~~'--~--'-20 ~---21 ----22
119-359 1
119-359 1
REMOVING AND INSTALLING COOLING SYSTEM COMPONENTS
a Draining and refilling coolant - Page 19-10.
a Chee k; ng coo I ant sys tem for lea ks - Page 19-14.
1- Coolant DiRe
2- Connector
a For coo I ant shortage ; ndt ca tor swi tch - F66 in expansi on tank
3- Expansi on tank
o Wi th coo I ant shortage i cd; cater swi tch -f66
4· lli
a Chee king - Page 19-14
15
14~ ~
~~
6
15==------ 14~
6
14- Radi ator
o To remove, remo
0late and frontV~ lock carrier
orkshop Manua I um~er - see
Body Repai " Audl 100 "G
63 rs , Repair General
o Lower roups 50 and
, coo I ant h
pos i t ion _ Fi ose: Install at'
15- g. 1, Page 19-9 ion
Upper air guide 16- 10 Nm
17- Angie bracket
18-
19-
20- Lower air guide 21- 10 Nm
o Important· He
22- L " verse-threaded I
_Qck washer
o Grabs into f
o Bend a an
ver one tooth to I k
23- tin DC nut
24- ~ 25- Fan motor 26- 10 Nm
27 - Fan frame
o For el eetri c fan
28- l.Q..Jjm
29- lli.R
c For wi re to fan
motor
19-4
22
119-360 1
1· Coolant pipe
2· 20 Nm
3- To radiator (bllll.Qml
a Ir s ta 11 at i on pes i ti on of lower coolant hose· Fig. 1, Page 19-9
4· 10 Nm
5· Un; on
6- ~
o For thermos tat
o Renew
7· Thermostat
o Installation pos i t icn v Fig. 2, Page 19·9
o Checki ng:
Heat thermostat in water Opens at apprcx , 87 "C Closes at approx , 102 '(
o Opening stroke at least 8 mm
8· Coolant pump
o Check shaft for ease of movement
o Renew coolant pump if damaged or 1 eaki ng
9- 20 Nm
19·5
10- Q.::r.iruI.
a Renew
a (1 ean and smooth sea 1 i ng surface
for O-ri 09
11- Br~,kgt fQr e1§ctric cQQ1~ol Qymp
o Mounted on 1 eft Engi ne support
12· 20 Nm
13- Cool ant pump
0 For turbocharger
a Checki ng - Page 19-16
14- El ectroni c thermoswi tch -F76
o Check; n9 - see Workshop Manua 1 Audi
100 "£1 ectri cal System"
a 25 Nm
15- Thermoswi teh . F9S
0 For turbocharger coal ant pump
o Switching temperatures:
on 106 - 112°C
off 94 - 105 °C
0 15 Nm
a Checki ng - Page 19·16
16- To radiatQr (tQQ)
17- To expansion tank 19-6
17 18 19 20 21
~4)~~ii~
------,.~~3ti ~. .. --+--22
16--- 15 14----
(
119-360 1
18- Coo 1 ant mani fa I Q
19- Gas ket
0 Renew
20- 0- ri n9
a Renew
21- 1lL1lm
22- Banjo bolt ~
a 30 Mm 23- Coo I ant pi pe
24- From heater· heat exchanger 25- Cool ant supply pipe
o To turbocharger
26- Coolant temperature sender -G62 o 15 Nm
a Checking - see Workshop Manual Audi 100 "Motronic Ignition and Injection System"
27- O-ring
o Renew
28- lin.i.Jm 29- 20 Nm
19-7
30- Sender for Ale coolant temperature -GUO
o Checking - see Workshop Manual Audi 100 "Heater and Air Conditioner"
31- ~nq
o Ren€w
32- Retaining clip 33- Union
34- To heater heat exchanger
19-8
<OIl Iig_.___l__j.nstallation posi ti.Q!LQf bot tom tOO I ant hose
Arrow marki ngs must be a Ii gned.
<OIl Fig. 2 Thermostat installation position
19-9
DRAINING AND FILLING COOLANT
/lQ.tf_;_
Coo ling sys tern is fi 11 ed a 11 year round wi th mi xture of water and Gll VB 6 ant i freeze and ant i-carras i on add it i ve. Gll va B and coo I ant addi t i ves marked as bei ng "i n accordance with TL VW 774 B" prevent damage due to freezi ng, corrosion and scale formation. In addition, they raise cool ing bailing point. For these reasons, coolant system must be filled all year round with anti-freeze and anti-corrosion additive.
Due to high boiling paint, coolant is an aid to operat i ana I effi c i ency when engi ne is operating at full load - particularly in countries with tropical climates.
Recommended mixture rat ros for 9.0 ltr. capaci ty:
Frost Gll V8 B Water
protect i on quant i ty quant i ty
down to
-25 O( 3.6 I tr. 5.4 I tr.
- 35 0(1) 4.5 ltr. 4.5 ltr. 1) For countries with cold climates
19-10
Note:
Catch coolant for proper disposal,
<II - Remove noise insulation,
Position catch basin V,A,G 1306 under engi ne compartment.
- Open expansion tank cap .
... - Drain coolant at radiator, p~shing auxiliary hose onto drain cock if necessary.
19-11
... Remove upper hose to radiator -1- at
radi a tor and cool ant manito 1 d and 1 ay aside, T-piece to expansion tank remains connected,
Remove ai r hose -2-,
... - Remove union -arrows-,
Take off O-ri ng and thermostat, all owi ng remaining coolant to run off.
19-12
VW 1274/1
£lllirlR;_
o Renew coo I ant.
I nsta II thermostat with new O-ri ng - installation position - Fig. 2, Page 19-9.
Fit union (10 ~m).
Install coolant hose.
"II Fi 11 cool ant up to upper edge of expansi on tank.
Close expans i on tank.
- Run engine until operating temperature has been reached (coo I ant temperature gauge at approx. so 'C).
- Check coolant I eve I and top up to marki ng if necessary. When engine is at operating temperature, cool ant I eve I must be somewhat above "MAX" mark. When engine is cald,
I evel must 1 i e between "MlN" and "MAX" marking.
19-13
CHECK! ~G COOLANT SYSTEM FOR LEAKS
o Carry out only when engine is at operating temperature.
"II - Fit cooling system tester VW 1274 to expansion tank with adapter VW 1274/1.
- Produce pressure of approx. 1.0 bar with hand p~mp of tester.
- if pressure drops within short time, locate 1 eak and repai r.
CHECKING PRESSURE RELI£F VALVE IN CAP
Screw cap onto coo ling system tester VW 1274 with adapter VW 1274/1.
- Produce pressure wi th hand pump of tester.
- Pressure relief valve must open at 1.2
1.5 bar.
19-14
CHECKING VISCOUS FAN
Visual check,
Check viscous clutch for oil leaks. Backside of clutch housing must be clean and dry.
- Check ease of movement of fan with engi ne switched off. It must be possible to turn fan wt thout noti ceable resistance.
Check axial clearance. Clearance should mea<ured at outer c i rcumference of fan - not exceed approx. 15 11l11.
Note:
o Function of viscous fan clutch cannot be checked in workshop.
a When renewing viscous clutch, watch installation position of fan - Page 19-1.
19-15
CHECKING TURBOCHARGER THERMOSWITCH -F98 AND COOLANT PUMP
Run engine unti I coolant temperature gauge indicates more than 100 "C (cover radiator if necessary).
Switch off engine.
After approx. 5 minutes, electric coolant pump and radiator fan must switch on.
o If electric coolant pump and radiator fan do not run:
Oi sconnect wi res to thermoswitch and connect to each other.
[1 ectric cool ant pump and radiator fan must run.
o If coolant pump and radiator fan run,
- Renew thermoswitch.
o 1 f· coo 1 ant pump and radi ator fan do not run:
- Eliminate fault using current flow diagram.
19-16
REMOVING AND INSTALLING FUEL SYSTEM COMPONENTS
~
When working on fuel system, respectively valid safety rules must be observed.
Note:
a Always renew gaskets oil seals and hose clips during repair ~ork.
a ~ose connections are secured with screw or spring clips.
a Connect remote control - Fig. 1, Page 20-3
o Checking fuel pump relay - see Workshop Manual Audl 100 "Motronic Injection and Ignition System".
o When removing and installing fuel gauge sender, make sure that wires are not damaged.
o Observe rules for cleanliness - Page 20-4
1- Supply pipe
D To fuel tank
o Installation position of fuel filter - fig. 2, Page 20-3
2- Return pi pe
20-1
3- Breather pj pe
o To activated charcoal filter
4- Pressure holding valve
o 0.02 '-_ 0.3 bar
o Prevents fuel from reach; ng activated charcoal filter if tank is overfi 11 ed
5- Overflow pj pe
6- filler pipe
7· MQn- return fl ap
8- Double clip
9- oo.tank
o RelOOving and inste l l itq >
Page 20-11
10- ~
o Prevent rubbi ng
11- ~
o 20 Nm 12- Locki n9 ri og
c Removing - Page 20-7
13- Fuel gauge sender
o Removi ng and install ing - Page 20-6
14-~
20-'1
... Fig. 1 Connecting remote control V.A.G 1348/3 A with adaQter Wi re V.A.G 134813-2
Pull fuse No. 17 out of fuse holder.
Connect remote control V.A.G 1348/3 A to contact of fuse socket of fuse No. 17
(i tem 2) with adapter wi re V. A. G 1348/3-2 and auxiliary wires from V.A.G 1594.
- Connect c 1 i p termi na 1 to battery (+).
On vehicles with air conditioner:
Connect clip terminal to starting aid socket [tl .
... Fig. 2 Install at jon position of fuel fi 1 ter
Arrow' Direction of flow to engine.
20-3
RULES FOR CLEANLINESS WHEN WORKING ON FUFL SUPPLY /INJECTION' SYSTEM
o Thoroughly clean all unions and surrounding areas before disconnecting.
o PI ace removed parts on cl ean surface and cover with fi 1 m or paper. Do not use
fl uffy cloths!
a Carefully cover or seal opened components if repai rs cannot be carri ed out
i mmedi ate 1 y.
o Only install clean parts.
- Only unpack replacement parts inmediately prior to installation.
- Do not use parts that have been stored loose (e.g. in toolboxes etc.)
o When fuel system is opened:
- Do not work wi th compressed ai r if avoidable.
Do not move vehi cl e unless absolute 1 y necessary.
20-4
SAFETY MEASURES WHEN WORKING ON FUEL TANK
When remov i 09 and ins ta II i ng fue I pump or fuel gauge sender from completely or parti ally filled fuel tank, the following must be observed:
o Before begi nni ng re pa irs, suction pi pe of exhaust extraction unit must be located near repair opening of fuel tank so that fuel vepours which escape after opening cap can be irrmediately sucked off.
If no exhaust extraction unit is avai lable, a radi a 1 fan (motor is located outs i de airflow) with volume of more than 15 mJ/hr. may be used.
o If it is necessary to reach into fuel when removing or installing fuel pump, fuel
res i stant gloves illII.S1 be worn.
20-5
REMOVING AND INSTALLING FUEL GAUGE SENDER
o Observe safety measures - Page 20-5.
Important!
Fuel tank must not be more than 2/3 full.
Removi n9:
~ - Remove cover (under I uggage boot floor covering) .
Pull off connector for fuel gauge and fuel pump.
~ - Loosen c l ips of supply pipe -A-, return pipe -8- and breather pipe -C- and pull off pipes.
Note installation position of fuel gauge sender - mark if necessary.
20-6
c
.. - Unscrew locking ring with spanner for sender 3087 and pull sender out of fuel tanx,
Note:
I,hen removing and installing fuel tank sender, ensure that wires are not damaged.
- Pu 11 supply and return pi pes off inner side of sender hous i ng.
Pull off electrical connection to fuel pump.
Installing;
- Watch installation position of fuel gauge sender.
20-7
REMOVING AND INSTALLING FUEL PUMP
o Observe safety measures - Page 20-5.
lmportantl
Fuel tank must not be more than 2/3 full.
Removing;
.. - Remove cover (under luggage boot floor covering) .
- Pu 11 off connector for fuel gauge and fuel pump.
.. - Loosen c 1 i ps of supply pi pe -A-. return pipe -8- and breather pipe -C- and pull off pipes.
- Note .i ns tal tat ion position of fuel gauge sender - mark if necessary.
20-8
.. - Unscrew 1 ocki ng ri ng with spanner for sender 3087 and pull sender out of fuel
tank. .
Note:
When removing and installing fuel tank sender, ensure that wi res are not damaged.
- Pull supply and return pi pes off inner 5 ide of sender haul i ng.
- Pull off electrical connection to fuel pump .
.. - Fit fuel pump spanner 3214 to fuel pump in baffl e housi ng and turn pump approx. 15 mm toward left.
Pullout pump upward.
20-9
Installing:
.. - Insert fuel pump into baffl e housing so that V-marking -C- aligns with marking -A-.
- Fit fuel pump spanner 3214 to fuel pump.
- Turn fuel pump clockwise until V-markin9
-C- a l i gns with marki n9 -8- (fue 1 pump
engages) •
- Watch ; nsta 11 ati on posit; on of fuel gauge sender.
20-10
REMOVING AND INSTALLING FUEL TANK
Removal instructions:
- Empty fuel tank before removing with fuel extractor V.A.G 1433!A.
Remove cover 1 n plenum chamber at ri qht and
di sconnect battery earthi ng strap. (On
vehicles with fresh air fi Iter or air
cond i t i oner , ba ttery j s located under rea r seat [",hi on.
- Remove rear final drive - see WOI'kshop Manual Audi 100 "5-Speed Manual Gearbox OIA 4-Whee I Dri v€" - Repa i r Group 39.
- To support, position engine!gearbox.lifter V.A.G 1383 A under fuel tank.
Installation instructions:
- Attach insulating strips and pipe attachments an new fuel tank using removed tank as a guide.
- I nsta II rear fi na I dri ve - See Workshop Manual Audi 100 "S-Speed Manual Gearbox OIA 4-Wheel Drive" - Repai r Group 3g.
3·---
20-11
DISMANTLING AND ASSEMBLING ,UEL PUMP
Note:
There are two baffle housing versions:
a- Baffle housing connected to fi Iter screen wi th bayonet fi tti ng.
b- Ba ffl e hous i n9 we I ded to fi Iter screen.
l- EI g.l[j .aJ "QOo~,tion
0 For fuel pump
2- ~
3- Baffle housing
4- Fi lt~r s,re~o
5- SUQ~ly ~i~~ 20-12
2
4
(HECKrNG FUEL PUMP
Checkj ng power sUDD I y
o Battery full y charged (at I east 12 V)
o Fuel filter in good condition
Connect remote control V.A.G 1348/3 A - Fig. 1, Page 20-5.
Operate remote contra I. Fuel pump must operate audi b ly.
Note:
In noisy surroundings, second mechanic may be required to listen for pump operating noises under vehi cl e near fuel tank.
o Fuel pump IlIl!..S.:
Check fuel pump relay - see Workshop Manua I Audi 100 "Matronic Injection and Ignition System", Repai r Group 01.
o Fuel pump ~..J:!!!l:
.. Unscrew cover for fuel gauge sender and fuel pump (under luggage boot floor caveri ng) .
- Pull off connector for fuel pump and fuel gauge.
20-13
-<III _ Connect hand multimeter V.A.G 1526 to
contacts 1 (green/yellow) and 4 (brown) with auxiliary wires from V.A.G 1594.
- Operate remote control.
Speci fi ed value: approx. battery vo ltage o If specified value is not obtained:
- E1 i mi na te break in wi ri ng using current flow diagram.
o If specified value is obtajned:
- Remove fuel gauge sender - Page 20-6.
-<III - Check wi res from sender hausi n9 to fuel
pump for continuity with hand multimeter and auxiliary wires.
- Eliminate break in wiring if necessary.
- If no brea kin wi ri ng is present, renew
fuel pump. Removing and installing fuel pump - Page 20-8.
20-14
== = ~ = ~~>~f!!~7:~ ~~~=: -- ~ =--~T-~
: -_ -~ I
<",311~")
90~
iIoo
I ....
.... 7DO
- 6DO
_,.. 40Q
./
--- ---- 300
---
I~
6 , 10 11 U 13 ,~ ~ .. )
rf6y.i] ... - ~1~Bth hose to sappl v piDe anj hal d in lJ'Eas-lrj~~ 91~5'.
20·15
• Operate ,...,mGt~ control V.A.~ 1348/3 A 'ilr l'i seconds (hold do-.-n button).
.. - Coop.re '11easur-ed ~UOII~ i t,Y -".i th spec i f i ed values f)r l'liniwul1I feed rate 1n gr!pr.
Mi ~imum feed rate me~sur~d H return
pi pe is em'fl" 5tC. -
~olt~ge ~t fuel pump -".ith ~n~1ne ~t~PPEd and pump runn--r.~ (app"()~. 2 ~ belGw battery voltage).
20-1 fj
(1IEeK! NG NQN"Rl_T~RN VALVE OF FuEL PUMP
1fst condition.:
o PressurE regulacor, fuel pump, injectors and f,e I fj I t er OK
o Wi ri ng sys tem OK
o 'oed rate of fue! pump 0" checking - Page 20-]5
o Battery fully charged (at least 12 V)
- Connect remote control V.A.G 134B/3 II with adapter wire V.A.G ]348/3-2 - Fig. I,
Page 20-5.
.... - Conned pressure gauge V.A. G BIB between fuel supply and fuel col iector pip.' with adapter V.A.G l318/11, V.A.G 1318/13 and V./I.G BI8/1'. Lever to pressure gauge in "open" position.
operate reroote control for approx. 30 seconds.
Move lever on pressure gauge to "closed" PO! i ti on .
.!!ili.;_
Pressure gauge lever must remain in "c lcsed" pas i t i on during neasur: ng procedure.
20-17
- Briefl y operate remote control unti I max. 5.5 bar ;5 indtceted.
Watch pressure drop:
after 10 nli n.: m1l~. 0.5 bar
If pressure drop is greater, carry out fo: low; 09 checks:
-. Check pressure gauge connect i ons for leak s ,
o Check fuel lines for leaks.
- [f no leaks are present, non-return valve 10 fuel pump is defective.
- Renew fuel pump - Page 20-8.
20-18
·~I -----------------1
L~:
:::~
~-------11
;' ~ ---------------12
2~~~
1r--------------l0
120-10361
1,;--------10
~--------------n ---------------12
120-10361
SERVICING FUEL TANK VENTILATION WJTH ACTIVATED CHARCOAL f I L TER
1- ~
o Ends in open on right-hand side of vehicle floor pan
2- 10 Nm
3- Self-tapping screw
a For ventilation valve
4- 10 Nm
5- Activated charcoal fi lter (ACFl
a Installation position, front right wheel housing,
o Hose connect ions - Fi g. 1, Page 20-21
6- Fuel gauge sender
7- Self-tapping screw
8- Sol enoj d val ve for act i voted charco" I fil ter
o Checking function and actue t i on - see Workshop Manual Audi 100 "Motronic Ignition and Injection System"
20-19
9- Hose
a To throttle housing
10- H2ll
o Hook into clip on activated charcoa I fi Her
11- Sealing ring o Renew
12- Ventilation valve
a Regulates vent t lation of activated charcoal fil ter
o Prevents spl ash water from reachi ng act i veted charcoal fi Iter
,
20-20
<II Fig., I Hose connections of activated charcoal fi Iter
1- To solenoid valve for activated charcoal fi Iter.
2- TD fuel gauge sender.
3
)20-1034 [
20-21
SERVICJN~ THROTTLE LI NKAGE 1- U_iQ
2- Lock; n9 [I; p 3- Locking clip
o For adjusting throttle cable
4- Throttl e cable
o Adjusting - Page 20-23
5- SQuare bearj n9
6· Throttle pedal 7- Locking cl ip
8- Bearj n9 sleeve
9· Stop bolt for throttl e pedal 10- ru!ltt
20·22
ADJUSTING THROTTLE CABLE
Note:
a Throttle cable is highly susceptible to kinki ng and must therefore be carefully handled when installing.
a Single, slight kink can lead to break
1 a ter. Therefore. throt tl e cabl e wh i ch has been ki n ked !ThU...D.Q1 be ins ta 11 ed.
o When installing, ensure that throttle (able ali gns between support bracket and fast idle cam.
Ad j ustment condi ti ons:
o Throttle cable connected to throttle pedal and fast idle cam.
o Securing clip pulled off throttle cable sleeve.
- Depress throttle pedal to full throttle pes i ti on.
- Pull back throttle cable sleeve until thrattl e va I ve I ever contacts full throttl e stop.
- Insert securing clip behind support bracket at locking segment of throttle cable sleeve.
20-23
3
2------
3
2-~---~-
fuLte: 1 s for cleanliness _
o Observe ru e .. s
Page 21-4.. secured Wl th c l i P •
o Hose connectlonSI are
o Alwa~s rene~o~~:r~~r wi th 0; 1 _
o H l l inq tur
Page 21-9.
1- .l.Q.Jlm
2- Qil return pipe
3- .l.Q.Jlm
4- Cool ant return pi pe
a 25 Nm riate plug after
a Sea 1 wi th approp
unscrewi ng
5·
Adapter a 30 Nm
Turbocharger 21-10
o Check1ng - ~agestalling _ Page 21-5
o Remov1ng an i n
6-
7-
Adapter o 35 Nm
21-1
8- 40 Nm
a Renew
9- Exhaust dow:~dilenstalling _ see
o Removlng 26.
Repair Group
10· Coolant s~pDly pipe
a 30 Nm riate plug after
o Seal with approp
unscrewing
11- 10 Nm 12· ~
o Renew
13- Banjo bolt a 25 Nm
14- CQrrugated Pi~~ t tcn position _ see
o Watch 1 nsta ~6' Repa·] r Group
15- 22___Ijj]
o Renew
16- Z2Ji!!l
o Renew
17- Waste gate 21.10
o Checking - ~a~~stalling _ Page 21-6 a Remavl ng an 1
18- Exhaust manitol d
21-2
14
2-------'
[3iiQQJ
19- 60 Nm
o Renew
20- Oil s~pply pipe
o Before screwi ng on, fi 11 oi I hole on turbocharger with engine oil - Page 21-9
21- ~
o For crankcase ventilation
o To cyl i nder head cover
22- Air hose
o To air volume sensor
23- Overrun cut-off valve
o ChecKing - Page 21-13
24- vacyym hose
o Vi a connect i n9 pi pe to inta ke mani fold
25- ~
o To pressure pipe
26- Solenoid valve for boost pressure 1 imiting -N75
o Checking - see Workshop Man"al Audi 100 "Motronic Ignition and Injection System"
21-3
RULES fOR CLEANLINESS WHEN I,ORKING ON rURBOCHARG[ R
o Thoroughly clean all unions and surrounding areas before di sconnect i ng.
o Place removed parts on clean surface and cover wHh fi 1m or paper. Do not use fluffy cloths!
o Carefully cover or seal opened components i f repalrS cannot be carried out
ill1l1edi ate ly.
o Only install clean parts.
- Only unpack replacement parts iTlllletiiately prior to installation.
- 00 not use parts that have been stored loose (e.g. in toolboxes etc.).
21-4
REMOVI NG AND I NSTALLI NG TURBOCHARGER
o Always renew seals, gaskets and self-
I ocki ng nuts.
- Oi sconnect earthi ng strap to battery. Note:
On vehicles without fresh air filter or air conditioner, battery is located in plenum chamber on right. On vehicles with fresh air filter or air conditioner, it is installed under rear seat cushi on.
.... - Remove ai r hose between air YO I umesensor and turbocha rger -4- at air vol ume sensor ,
- Pull connector off air volume sensor -3-.
- Unscrew retaining bolt -1-.
- Loosen four spring clips -2-.
- Take off upper section of air cleaner
housing and filter insert.
- Oi sconnect intake hOse and remove lower section of air cleaner housing.
21-5
Removing waste gate;
.... - Unscrew control pipe from waste gate.
~
Store banjo bolt so that it cannot become di rty or damaged.
Unscrew corrugated pi pe from exhaust pi pe.
Unscrew waste gate from exhaust manifold.
Removi ng turbocharger;
.... - Unscrew hose between air volume sensor and turbocharger at turbocharger -arrov-.
- Unscrew crankcase venti I at i on pi pe -arrov-.
- Pull off vacuum hose and hose to pressure pi pe from overrun cut-off va 1 ve.
21-6
<III - Pull sol enoi d va 1 ve for boost pressure
1 i mit i n9 -8- out of bracket.
- Remove hose between so I enoi d v« I ve for boast pressure limit i n9 and turbocharger -arrow-.
<III _ Unscrew four nuts on turbocharqerrexhaust
dawn pi pe fl ange -arrows-.
Note,
a To loosen lower rear nuts on turbocharger/exhaust down pipe flange, flat ring spanner (SW 15) must be bent to fit -arrow in lower diagram-.
a Other nuts on turbocharger/exhaust down pipe flange are spanner size 17.
Remove exhaust down pi pe - see Repai r Group 26.
21-7
Note:
o After unscrewi ng coo I ant pi pes these must be plugged inmedi ate ly with suitable plugs.
o Make sure that no coolant reaches turbocharger oil passages.
<III - Unscrew coolant supply pipe -C- and oil
s upp ly pi pe - D- from turboche rger.
<III _ Unscrew hose from turbocharger to
intercooler at turbocharger -ar-ov-,
Unscrew oil return pipe at bottom of turbochilrger.
Unscrew coolant return pipe from turbocharger.
21-8
.... Unscrew turbocharger from exhaust manifold.
Installing:
• Fi rst screw turbocharger onto exhaust manifold.
· Cannect to coolant 1 ines to oi 1 return pi pe.
· Before screwing on oil supply pipe, fill oi 1 passage on turbocharger with oi 1.
· Watch i nsta 11 at i on pes it i on of corrugated pi pe • see ~epai r Group 26.
· Run engine at idle for approx. 1 minute after installing turbocharger. Do not rev up, as oi 1 supp Iy of turbocharger is not yet ensured.
21·9
CHECKING TURBOCHARGER AND WASTE GATE
Test conditions
o Interrogate fault memory· see Workshop Manual Audi 100 "Motronic Ignition and Injection System"
o Carry out final control element diagnosis. see Workshop Manual Audi 100 "Motroni c Ignition and Injection System"
o Eng i ne oi 1 temperature at 1 east 30 "C
o No leaking vacuum connections
... Turn quick fasteners -arroes- on connector cover on rear engine compartment bul khead gO' to 1 eft and remove cover .
... . Oi sconnect moi sture separator ·1· from bracket ·2· and pul1 off hose ·3·.
• Fi t T ·pi ece with measu ri ng hose of turbocharger tester between mei sture separator ·1· and disconnected hose.
21-10
• Route measuri n9 hose over rear edge of bonnet and through right window opening into vehicle interior .
... . Switch on turbocharger tester, sWitch measuring range switch to position ·1· and attach measuri ng hose to un i on • I·.
Note:
a Hoses must be connected absolutely leakfree. as otherwi se measuri n9 errors are possible.
a By press i n9 memory button M on turbocharger tester, last measuring value is stored
unt i I memory button Mis pressed again or tester is switched off.
o Storage in memory is indicated by blinking of decimal point in display.
o If battery voltage of turbocharger tester drops below permissible limit, arrow appears in upper I ef't-hand corner of display.
o Before checking, drive vehicl e briskly for at least 3 km (no traffic lights etc.)
a As boost pressure is measured during driving, second mechanic must be present to operate turbocharger tester for safety reasons.
21·11
Fully depress accelerator in ~th gear when road speed is approx. 60 km/i'. and observe rev. counter .
... . Press memory button M on turbocharqer tester at 3000 rpm.
Specified value:
Altitude {m} Outside temperature
Boost pressure (bar)
o . 1600
o . 1600
o . 1600
1.840 . 2.000 1.990 - 2.100 2.030·2.150
0' 20' 3~'
o = Sea I eve I
For intermediate values of outside temperature, boost pressure val ues may deviate slightly.
If specified value is obtained, but poor performance is noti ced in speed range be low 2500 rpm. check overrun cut-off valve > Page 21·13 .
• If specified value is not obtained, temporarily renew waste gate and repeat chec k ,
If specified value is still not obtained. renew turbocharger.
21·12
CHECKING OVERRUN CUT-OFF VAl VE WITH VACUUM PUMP V.A.G 1390 .
o Over-run cut-off va I ve is located in front of turbocharger. It opens overrun phase with vacuum pressure, thus relieving existing boost' pressure in front of throttle valve in order to prevent load shock during acceleration/deceleration changes.
a If performance is down or shock I Dads occur duri n9 load changes, overrun cut-off valve must be checked.
<ill _ Attach vacuum pump V.A.G 13QO to overrun
cut-off va I ve.
Operate vacuum pump.
a Overrun cut-o+f valve must open -arros-. - After approx. 30 seconds, operate vent I ng val ve of vacuum pump.
o Overrun cut-off valve must close -arrow-.
If overrun cut-off valve does not open or close, or if valve plate is leaking with cut-off closed, renew valve. Secure connections of overrun cut-off valve with hose cl ips.
9----..- ... 8 -------<r .....
7
11
12
6
5
I
4
I
L ___ 2 1
'---16
1 21-0981
21-13
REMOVING AND INSTALLlNG INTERCOOLER COMPONENTS
Note:
All hose connections are secured with cl i ps.
1- 20 Nm
2- Pressure pipe
3-~
a To turbocharger
o Wi th branch to overrun cut-off val ve
4- ZQ.l!m
5" Front angle bracket
6- Rubber grorrmet
o For front ang I e brae ket
7- Intercooler
8- Rear angl e bracket 9- Rubber gromnet
a For rear angle bracket
10- Cheese-head bolt with collar o 20 Nm
21·14
11- 2.Q.JJm
11- Se I f-t~~~i ng ~C[eli
0 for sec~ring air guide
13- Ai.r..sY.i.J!.e
14- Se If-ta~~i 09 screw
0 For securing air guide
15- Ai r hose
.> o To intercooler
16- 2O.1Im
12 6-L-----;;. 5-!---~""' 4-L--~
-- • __ c
-c_-7
'15
~16 121:0981
REMOVING AND INSTALLlNG INTERCOOLER
13
11-15
- Remove front b~mper - see Workshop Manua I Audi 100 "Genera I Body Repai rs", Repai r Gro~p 63.
- Unscrew reservoir for hydraulic fluid from engine compartment sidewall and put aside with 1 i nes connected.
- Unscrew wi ndscreen washer water reservo; r.
- Disconnect two air hoses at intercooler.
- Unscrew rear securing bolt from i ntercoo 1 er.
<II Remove bolts from front bracket -arrows-.
- Take off intercooler downward.
11-16
REMOVING AND INSTALLlNG EXHAUST SYSTEM COMPONENTS
Note:
o Renew gaskets, seals and self-locklng nuts.
o Install retainlng rings and bands In accordance with parts 1 i st
o Ensure sufficlent space between exhaust system and body.
o ATlgn exhaust system tension-free - Page 26-7.
1- Main si"lencer
o Combined with rear silencer to form one unit
o Separating point is provided for renewing indlvidual silencer - Fig. 5, Page 26-6
2 - 25 Nm
o Parts arrangement - Fi g. 1, Page 26-4
3- 25 Nm
4- Seal ing ri ng
o Sensi tive to impact - do not drop
126-7251
26-1
5- QJ!m
o Arrangement of Darts - Fi g. 2,
14 Page 26- 4
lS 6- Ca ta 1 ys t
16 7- Exhaust manifol d gas!et
17 0 Fl anged surface must face exhaust
man i fa 1 d
18 0 Renew
8~ Exhaust m~nifold
o To remove, remove turbocharger -
see Repa i r Group 21
9- QJ!m
0 Renew
10- £2.Jlm
0 Renew
11- Waste gate
0 Removing - see Repalr Group 21
12- Turbocharger
0 Removi ng - see Repai r Group 21
13- .2iJlm
0 Renew
14- CQrrug~tgd Rige
0 Installation position - Fig. 4,
Page 26-5
26 126-725)
26-2
l~--~t~ 1~~A~~Y~14
~v ~ r1:t==15
9 I -, i'j-I!JV 16
? I I) '~ v 17
:~~\1. ~~
~,~~::
. __ . __ ._- __j
5
15~ Lambda ~rQbl:
c 50 Nm
16~ CO measuri DS tube
o 20 Nm
17- I!Sl5.ktl
0 Renew
18- 25...Jjffi
0 Renew
19- JO_Jjm
0 Renew
20- 60.Nm
0 Renew
21- I!Sl5.ktl
0 Renew
22- E~b~~H dQwn ~i ~e 23- Centre exhaust pi pe
24- 40 Nm
25- Double pipe clamp
o Renew after unscrewing one bolt
o Installation pos t tlcn - Fig. 6, Page 26-5
26- Rear sj I encer
o Combined with main silencer to form
one unit '
a Separating point is provided for renewi ng i ndi vi dua I si I encer - Fig. 5, Page 26-6
26-3
<II Fig. 1 Centre catalyst/exhaust piQe fastener
o Arrangement of parts: 1- Nut (25 Nm)
Arrow - Flange position 2- Spri n9
3- Sleeve
4- Washer
5- Bolt
<II Eig_, 2 Bracket
o Arrangement of parts [., Catalyst
2- Bolt
3- Washer
4- Spri n9
5- Bracket
6- Sleeve with shoulder 7- Washer
8- Nut
26-4
.. Fig. 3 Double pipe clamp
o Installation position:
Pipe clamp must contact stop tabs -arrows-.
Note:
Renew double pipe clamp each time fastener is loosened.
.. Fi g. q Corrugated pi pe
a Installation position:
Oi rect i on of flow -arrow- from exhaust manifold to exhaust system.
26-5
.. Fig. 5 Separating point between main and rear s i I encer
Separating point is provided for renewing main or rear silencer.
Dimension a 0 130 mm Dimens i on b = 130 mm
26-6
ALIGNING EXHAUST SYSTEM TENSION-FREE
o Exhaust system is aligned while cold.
- Ensure sufficient clearance between all pa rts of exhaust system and body •
... - When exhaust system is correctly fitted, pretens i on at rear mounts of rear si 1 encer must be -a- " approx. 10 mm.
26-7
CHECKING EXHAUST SYSTEM FOR LEAKS
Leaks in exhaust system upstream of Lambda probe may lead to following malfunctions:
Starting probl ems Engine stalling
o Shaking at idle
a Uneven acceleration a Poor progressi on
Test conditions:
o Eng i ne cold or hand warm a 00 not run engi ne
- Insert compressed air gun into one exhaust system tailpipe and seal with rag.
Also seal second tailpipe with rag.
Set operating pressure of compressed air system to approx. 6 bar.
- Operate compressed air gun continuously.
Spray connect] on poi nts of cyl i nder head, manifol d, manifold/exhaust pipe, exhaust pipe/catalyst, connection points behind catalyst etc. with leak detection spray (commercially available) and watch for bubbles.
- Repair any leaks found.
Only use sealing compound in special cases.
26-8
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