Repair and service Audi A8 in body D2 with 1994 for 1999 of release.
1. Car operation
2. Maintenance service
3. Petrol engines of 2,8 l
4. Petrol engines of 3,7 and 4,2 l
5. Diesel engines of 2,5 l
5.1. The general data
5.2. Recommendations about engine removal
5.3. A pulley of the pump of the amplifier of a steering
5.4. A poliklinovoj belt
5.5. A gear belt
5.6. A cranked shaft
5.7. A head of the block of cylinders
5.8. The klapannyj mechanism
6. Diesel engines of 3,3 l
7. Systems of ignition and injection of fuel of petrol engines
8. System of release of the fulfilled gases of cars with petrol engines
9. The power supply system of diesel engines
10. System of prestarting heating of diesel engines
11. System of release of the fulfilled gases of cars with diesel engines
12. Greasing system
13. Cooling system
14. Coupling
15. A transmission
16. Shaft of a drive of forward wheels
17. Features of a design of transmission of all-wheel drive cars
18. A suspension bracket
19. Wheels and tyres
20. A steering
21. Brake system
22. A body
23. Heating and air-conditioning system
24. An electric equipment
25. Electric schemes
 










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5.7. A head of the block of cylinders

Forward section of an inlet collector
Switch off ignition and disconnect a wire of "weight" from the storage battery.

Fig. 3.3–24. An arrangement of screws of fastening of a casing of the engine



Turn out screws and remove an engine casing (fig. 3.3–24 see).
Disconnect a vacuum hose of management of a folding shutter at its presence.
Disconnect a hose of an air inlet from a folding shutter and move hoses aside.


Fig. 3.3–51. A head of the block of cylinders: 1 – a head of the block of cylinders; 2 – a lining of a cover of a head of the block of cylinders; 3 – bolts of fastening of a head of the block of cylinders; 4 – a cover of a head of the block of cylinders; 5 – маслоотражательное a ring; 6 – a lining; 7 – a cover; 8 – fuel tubes of atomizers; 9 – tubes of return of fuel; 10 – a sealing ring; 11 – a hollow bolt, 5 Н·м; 12 – an inlet collector; 13 – a bolt, 10 Н·м; 14 – a lining; 15 – the aligning plug; 16 – a nut, 10 Н·м; 17 – a thermofilter of the vacuum pump; 18 – a bolt; 19 – the vacuum pump, 10 Н·м; 20 – sealing rings; 21 – a lining of a head of the block of cylinders



Fig. 3.3–52. An arrangement of bolts of fastening of forward section of an inlet collector



Unscrew bolts and remove forward section of an inlet collector (fig. 3.3–52).
Installation is spent to sequences, return to removal.

The left section of an inlet collector
Remove forward section of an inlet collector.

Fig. 3.3–4. An arrangement of bolts of fastening of a thermofilter over турбокомпрессором



Unscrew bolts and remove a thermofilter over турбокомпрессором (fig. 3.3–4 see).
Mark and disconnect fuel tubes from atomizers.
Release and move aside a plait of wires from the left section of an inlet collector.

Fig. 3.3–53. An arrangement of bolts of fastening of the left section of an inlet collector



Unscrew bolts and remove the left section of an inlet collector (fig. 3.3–53).
Installation is spent to sequences, return to removal.

The right section of an inlet collector
Remove forward section of an inlet collector.
Disconnect vacuum hoses from турбокомпрессора and mechanical system valves рециркуляции the fulfilled gases and move hoses aside.
Mark and disconnect fuel tubes from atomizers.
Release топливопроводы and take them aside from the right section of an inlet collector.

Fig. 3.3–54. An arrangement of bolts of fastening of the right section of an inlet collector



Turn out bolts and remove the right section of an inlet collector (fig. 3.3–54).
Installation is spent to sequences, return to removal.

The left cover of a head of the block of cylinders
Remove forward section of an inlet collector.
Release and move aside a plait of wires from the left cover of a head of the block of cylinders.
Mark and disconnect fuel tubes from atomizers.

Fig. 3.3–55. An arrangement of nuts of fastening of the left cover of a head of the block of cylinders and a tube (1) returns of fuel



Unscrew hollow bolts and remove tubes of return of fuel 1 (fig. 3.3–55) from atomizers.
Unscrew nuts and remove the left cover of a head of the block of cylinders.
Installation is spent to sequences, return to removal, taking into account the following.
Replace sealing rings of tubes of return of fuel.
Replace the damaged lining of a cover of a head of the block of cylinders.
If sealing rings of fuel atomizers are damaged, it is necessary to replace a cover of a head of the block of cylinders.
Degrease a surface interfaced to a lining of a cover of a head of the block of cylinders.

Fig. 3.3–56. Places of drawing of hermetic before installation of a cover of a head of the block of cylinders



Put a thin continuous layer of hermetic on a semicircular surface (fig. 3.3–56) in an end face of a head of the block of cylinders.
Put sites of projections of 5 mm a layer of hermetic in diameter of 3 mm on external covers of a camshaft (fig. 3.3–56 see).
Nuts of fastening of a cover of a head of the block of cylinders tighten gradually and cross-wise.
Connect fuel tubes.
Establish forward section of an inlet collector.

The right cover of a head of the block of cylinders
The prevention
All clips and collars which at removal of a cover of a head of the block of cylinders will be damaged or cut, it is necessary to replace with covers of a head of the block of cylinders new at installation.

Turn away screws and remove an engine casing (fig. 3.3–24 see).
Loosen the collars also remove an air branch pipe from the air filter.

Fig. 3.3–57. Fastening of pipes to турбокомпрессору



Loosen the also remove pipes with турбокомпрессора (fig. 3.3–57).
Mark and disconnect fuel tubes from atomizers.
Release and move aside a plait of wires from the right cover of a head of the block of cylinders.
Unscrew bolts and remove a pipe connecting турбокомпрессор with a cooler of air.
Unscrew a bolt of fastening of a pipe for probeа engine oil level.
Unscrew hollow bolts and remove tubes of return of fuel.
Unscrew nuts and uncover heads of the block of cylinders.
Installation is spent to sequences, return to removal, taking into account the following.
Replace sealing rings of tubes of return of fuel.
Replace the damaged lining of a cover of a head of the block of cylinders.
If sealing rings of fuel atomizers are damaged, it is necessary to replace a cover of a head of the block of cylinders.
Degrease a surface interfaced to a lining of a cover of a head of the block of cylinders.
Put a thin continuous layer of hermetic on a semicircular surface (fig. 48 see) in an end face of a head of the block of cylinders.
Put sites of projections of 5 mm a layer of hermetic in diameter of 3 mm on external covers of a camshaft (fig. 3.3–56 see).
Nuts of fastening of a cover of a head of the block of cylinders tighten gradually and cross-wise.
Connect fuel tubes.

The left head of the block of cylinders
The prevention
All clips and collars which at removal of a cover of a head of the block of cylinders will be damaged or cut, it is necessary to replace with heads of the block of cylinders new at installation.

Before a detachment of the storage battery find out, whether there is at you a code of inclusion of a radio receiver.
Switch off ignition and disconnect a wire of "weight" from the storage battery.
Merge cooling liquid from cooling system.
Remove a gear belt from camshaft pulleys.
Remove forward section of an inlet collector.

Fig. 3.3–58. An arrangement of screws of fastening left (1), top (2) and the right (3) casings of a gear belt



Turn away screws and remove the top section of a casing of a gear belt 2 (fig. 3.3–58).
Turn away screws and remove left 1 and the right 3 casings of a gear belt.
Loosen the collars, unscrew three bolts and remove hoses of system of cooling from the forward party of the engine.
Disconnect electric wires from candles накаливания.
Turn out a bolt of fastening of the valve of system рециркуляции the fulfilled gases to the left section of an inlet collector.
Release and move aside a plait of wires from the left head of the block of cylinders.

Fig. 3.3–11. An arrangement of collars of fastening of hoses of system of cooling to heater unions on a partition of a motor compartment



Loosen the collars (fig. 3.3–11 see) and disconnect hoses of system the coolings going to a heater.
Loosen the collars also disconnect hoses from a pipe of system of cooling, and also unscrew a bolt of fastening of a pipe.
Mark and disconnect fuel tubes from atomizers.
Unscrew hollow bolts and remove from atomizers of a tube of return of fuel 1 (fig. 3.3–55 see).
Unscrew nuts and uncover heads of the block of cylinders.

Fig. 3.3–59. Sequence of a tightening of bolts of fastening of a head of the block of cylinders



In sequence, return to a tightening, gradually loosen the, and then unscrew completely bolts of fastening of a head of the block of cylinders (fig. 3.3–59).
Remove a head of the block of cylinders and establish it on the soft basis.

The right head of the block of cylinders
The prevention
All clips and collars which at removal of a head of the block of cylinders will be damaged or cut, it is necessary to replace with heads of the block of cylinders new at installation.
Before a detachment of the storage battery find out, whether there is at you a code of inclusion of a radio receiver.
Switch off ignition and disconnect a wire of "weight" from the storage battery.
Merge cooling liquid from cooling system.
Remove the right final collector together with a reception exhaust pipe.
Remove a gear belt from camshaft pulleys.
Remove forward section of an inlet collector.
Loosen the also remove pipes with турбокомпрессора (fig. 3.3–57 see).
Unscrew bolts and переметите aside a cover of the air filter, without disconnecting from it hoses.
Remove the case of the air filter.
Unscrew bolts and remove a thermofilter over турбокомпрессором (fig. 3.3–4 see).

Fig. 3.3–12. An arrangement of an electric socket of the gauge (1) in a hose (2) givings of air to an inlet collector



Disconnect an electric socket from the gauge of 1 air branch pipe (fig. 3.3–12 see).
Remove a hose of giving of air 2 to an inlet collector.

Fig. 3.3–60. Fastening of a tube of giving of oil to турбокомпрессору  and to an inlet collector


Disconnect a tube of giving of oil from турбокомпрессора (fig. 3.3–60).
Disconnect a tube of giving of oil from an inlet collector (fig. 3.3–60 see).

Fig. 3.3–61. An arrangement of bolts (1) fastenings of a pipe (2) systems of cooling and a direction of its moving



Fig. 3.3–62. Marks of a lining of a cover of a head of the block of cylinders by apertures (1), number (2) and a code of manufacture (3)



Unscrew two bolts of fastening of a pipe of system of cooling, move it to a back part of the engine and leave in this position (fig. 3.3–61).
Unscrew a bolt of fastening of the right pipe of system of cooling to an intermediate ledge, without separating a pipe.
Unscrew bolts of fastening of the right pipe of system of cooling to a head of the block of cylinders.
Unscrew bolts and remove the top casing of a gear belt.
Remove the right inlet collector.

Fig. 3.3–2. An arrangement of a clamp of a casing and a turn direction at removal of the fan of a radiator from an electric drive



For removal of the fan of a radiator from an electric drive disconnect from the fan an electric socket, take a casing clamp, then turn a casing counter-clockwise (fig. 3.3–2 see) and remove the fan.
Unscrew bolts of fastening of the generator, but do not disconnect from it a wire.
Unscrew a bolt of fastening of a pipe for the index (probeа) engine oil level.
Unscrew hollow bolts and remove tubes of return of fuel 1 (fig. 3.3–55 see) from atomizers.
In sequence, return to a tightening, gradually loosen the, and then unscrew completely bolts of fastening of a head of the block of cylinders (fig. 3.3–59 see).
Remove a head of the block of cylinders and establish it on the soft basis.

Preparation of a head for installation
Privalochnye surfaces of a head and the block of cylinders should be absolutely pure. For their clearing use a firm plastic or wooden scraper. At clearing be careful, as the aluminium alloy is very easy for damaging. Be convinced that the deposit has not got to oil and water channels. It is especially important for greasing system as the deposit can block oil giving to engine details. If necessary clean channels.
Check up привалочные surfaces of a head and the block of cylinders on presence of notches, deep scratches and other damages. Small defects can be removed machining. At detail major defects are subject to replacement.
Check up planeness привалочной surfaces of a head of the block of cylinders.
Clean apertures under bolts in the block. Bolt screwing up in the aperture filled with oil can break off the block because of the raised hydraulic pressure.

Installation of a head of the block of cylinders
Installation is spent to sequences, return to removal, taking into account the following.
At installation of a head of the block of cylinders it is necessary to replace on new self-locking nuts and bolts which tightened доворачиванием on a certain corner, and also sealing rings and linings.
The new lining of a head of the block of cylinders is necessary for taking from packing directly ahead of installation.
If on the engine new pistons are established, it is necessary to measure выступание pistons from the block of cylinders and according to this value to choose a thickness of a new lining of a head of the block of cylinders (fig. 3.3–59).
Выступание        Number
Pistons, mm        of apertures
                 0,39-0,49 1
                0,49-0,54 2
                0,54-0,65 3

Establish a lining on directing pins, thus an inscription «oben» should be directed to a head.
If works on клапанном the mechanism were spent, turn manually the engine on two complete revolutions to be assured that pistons have not hit about valves.

Fig. 3.3–37. An arrangement of the adjusting screw 3242 for fixing of a cranked shaft



Before installation of a head of the block of cylinders establish the piston of the first cylinder and a camshaft in ВМТ in a compression step. Fix a cranked shaft in this position, having unscrewed the gauge of the moment of injection of fuel from the block of cylinders and instead of it having screwed in the adjusting screw 3242 (fig. 3.3–37 see).
Insert bolts of fastening of a head of the block of cylinders and tighten them by hand, and then in the sequence shown in drawing 3.3–59, in four stages:
1st–35 Н·м;
2nd–60 Н·м;
3rd – to tighten on a corner 90 °;
4th – to tighten on a corner 90 °.
Further it is not required additional pulling up of bolts of fastening of a head of the block of cylinders.
Establish a cover of a head of the block of cylinders.
At installation of a directing pipe for the index (probeа) engine oil level it is necessary to establish a new sealing ring.
Establish a gear belt.
Establish a final collector.
Establish полиwedge a belt.
Fill in a fresh cooling liquid.
Remove air from the power supply system fuel.
Connect "a weight" wire to the storage battery.
Include a radio receiver and enter into it a code.
Lift glasses electric glass lifts upwards against the stop. Then press all switches стеклоподъемника once again, at least for 1 second, in position of closing for activation of the block of management glass lifts.
Establish time for hours.


5.6. A cranked shaft

5.8. The klapannyj mechanism