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
6. Diesel engines of 3,3 l
6.1. The general data
6.2. Removal and engine installation
6.3. A forward cross-beam of a motor compartment
6.4. A poliklinovyj belt
6.5. A gear belt
6.6. A cranked shaft
6.7. The left cover of a head of the block of cylinders
6.8. The right cover of a head of the block of cylinders
6.9. Removal of the left head of the block of cylinders
6.10. Removal of the right head of the block of cylinders
6.11. A camshaft
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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6.10. Removal of the right head of the block of cylinders


Fig. 3.4–52. A head of the block of cylinders: 1 – a forward average pipe of system of cooling; 2 – a bolt, 10 Н·м; 3 – a sealing ring; 4 – a head of the block of cylinders; 5 – the directing plug; 6 – bolts of fastening of a head of the block of cylinders; 7 – a connecting pipe of system рециркуляции the fulfilled gases; 8 – a bolt, 10 Н·м; 9 – a lining; 10 – a pipe of system of ventilation картера; 11 – a bolt, 10 Н·м; 12 – the vacuum pump; 13 – a bolt, 10 Н·м; 14 – sealing rings; 15 – a bolt, 20 Н·м + to tighten on a corner 90 °; 16 – a lining; 17 – a directing pipe for the index (probeа) oil level; 18 – a bolt, 10 Н·м; 19 – a lining of a head of the block of cylinders


Fig. 3.4–53. An arrangement of bolts of fastening of the left pipe рециркуляции the fulfilled gases and турбокомпрессора to a final collector



Unscrew bolts and disconnect the left pipe рециркуляции the fulfilled gases (fig. 3.4–53 see).
Unscrew fastening bolts турбокомпрессора to a final collector (fig. 3.4–53 see).
Unscrew bolts of fastening of the fuel heat exchanger.
Disconnect an average pipe of system of cooling from the back party of a head of the block of cylinders.

Fig. 3.4–50. An arrangement returnable топливопровода (1) and electric sockets (2–7).



Disconnect electric sockets from atomizers (fig. 3.4–50 see).
Unscrew a clip of fastening of wires and take wires aside (fig. 3.4–50 see).
Release from clips submitting топливопровод 1 (fig. 3.4–50 see) and remove it from atomizers.

Fig. 3.4–51. An arrangement of a collar of fastening (1) fuel hoses to the T-shaped splitter and fastening топливопровода (2) to the submitting fuel pump



Loosen the a collar also remove a fuel hose from the T-shaped splitter (fig. 3.4–51 see).
Remove spring bracket and disconnect топливопровод from the submitting fuel pump (fig. 3.4–51 see).
Disconnect топливопроводы about the right cover of a head of the block of cylinders.
Unscrew a stopper маслоналивной mouths.

Fig. 3.4–43. A dredging arrangement in an aperture маслоналивной mouths



For a bolt of fastening of a pulley of a cranked shaft turn a shaft until in an aperture маслоналивной mouths dredging (fig. 3.4–43 see) will not be visible.

Fig. 3.4–44. An arrangement of bolts of fastening of casings of fuel atomizers



Unscrew bolts of fastening of casings of atomizers, pull casings upwards and turn them on 90 ° counter-clockwise (fig. 3.4–44 see).

Fig. 3.4–45. An arrangement of bolts of fastening of fuel atomizers



Unscrew opened bolts of fastening of atomizers (fig. 3.4–45 see).
Pull upwards and remove atomizers of cylinders 1 and 3. At removal of atomizers it is possible to take advantage of the lever.
Turn a cranked shaft clockwise on 180 ° and remove atomizers of cylinders 2 and 4.

Fig. 3.4–46. An arrangement of bolts of fastening of a cover of a head of the block of cylinders



Unscrew bolts and remove the right cover of a head of the block of cylinders (fig. 3.4–46 see).

Fig. 3.4–55. An arrangement of bolts of fastening of a directing roller and a back casing of a gear belt



Unscrew bolts and remove back casings of a gear belt (fig. 3.4–55, 3.4–58 see).

Fig. 3.4–58. An arrangement of bolts of fastening of a back casing of a gear belt



Disconnect топливопроводы from ТНВД.
Disconnect an electric socket from the gauge of temperature of a cooling liquid.
Unscrew bolts and remove an average pipe of system of cooling.
Unscrew bolts and uncover the right head of the block of cylinders (fig. 3.4–46 see).

Fig. 3.4–57. An arrangement and sequence of an inhaling of bolts of fastening of a head of the block of cylinders



Unscrew bolts and remove the right head of the block of cylinders (fig. 3.4–57).

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. Check up, that the deposit has not got to oil channels and channels of system of cooling. It is especially important for greasing system as the deposit can block oil giving to engine details. If necessary clear 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 eliminated machining. At major defects replace details.
Clear apertures under bolts in the block. Bolt screwing up in the aperture filled with oil can entail rupture of the block because of excessive hydraulic pressure.

Installation of a head of the block of cylinders
At installation it is necessary to use new bolts of fastening of a head of the block of cylinders.
All clips and collars which at engine removal have been damaged or cut, it is necessary to replace with the new.
At installation 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.
Check up planeness привалочной surfaces of a head of the block of cylinders.
At replacement of a head of the block of cylinders and its linings in cooling system it is necessary to fill in a fresh cooling liquid.
The new lining of a head of the block of cylinders is necessary for taking from packing directly ahead of installation.

Fig. 3.4–59. Measurement выступания pistons from the block of cylinders



If on the engine new pistons are established, it is necessary to measure выступание pistons from the block of cylinders (fig. 3.4–59).

Fig. 3.4–60. Marks of a lining of a cover of a head of the block of cylinders by apertures (1), number (2) and the party of installation (3)



On the basis of size выступания pistons choose a thickness of a new lining of a head of the block of cylinders (fig. 3.4–60).

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 there was no blow of pistons about valves.

Fig. 3.4–61. 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 a compression step. Fix a cranked shaft in this position. For fixing of a cranked shaft from the block of cylinders unscrew the gauge of the moment of injection of fuel and instead of it screw the adjusting screw 3242 (fig. 3.4–61).
Using a screw-driver edge as the lever, uncover, closing a camshaft end face on a head of the block of cylinders.

Fig. 3.4–36. An arrangement of the clamp 3458 defining position of a camshaft



Establish instead of a cover a clamp 3458 defining a starting position of a camshaft (fig. 3.4–36 see).
Insert bolts of fastening of a head of the block of cylinders and tighten them by hand.
In the sequence shown in drawing 3.4–57, tighten bolts of fastening of a head of the block of cylinders in four stages:
1st – the moment 35 Н·м;
2nd – the moment 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.

The left head of the block of cylinders
At installation of a directing pipe for the index (probeа) oil level it is necessary to establish a new sealing ring.

Both heads of the block of cylinders
Establish a gear belt.
Establish a cover of a head of the block of cylinders.
Fill in a fresh cooling liquid.
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.


6.9. Removal of the left head of the block of cylinders

6.11. A camshaft