Cam belt and Head gasket change!

[porkkis]

Only 6 bolts and mine was quite tight also...

[Doug_RS2]

Look at Mikes website for help with that cam cover:

link

Have you unscrewed those threaded pems (never heard that description before) - see Mikes pics.

[Glen Chamberlain]

Excellent! thanks for that Doug! i wasn't aware of them two thingies! top man!

[Martynf]

Glen,

I kow the feeling with days of work rather than hours! felt the same when I ripped mine apart!

If it helps you, here's a link to the RC change on mine: http://www.vagparts.com/S2/D3/rad3.htm

Martyn

[Glen Chamberlain]

Originally posted by Martynf
Glen,

I kow the feeling with days of work rather than hours! felt the same when I ripped mine apart!

If it helps you, here's a link to the RC change on mine: http://www.vagparts.com/S2/D3/rad3.htm


IMartyn

'll probably use it for re-assembley cos my memory is like a? dam cant quite remember what its like now????? :confused:

[Josh-stateside]

Cylinder head
Disassembling and assembling

Note: Cylinder head can be removed and installed with engine installed.
Removing and installing toothed belt Repair Group 13
Removing and installing fuel injectors


Repair Manual, 2.22 Liter 5-Cyl. Turbo Fuel Injection & Ignition, Engine Code(s): AAN

Cylinder heads with cracks between valve seats or between valve seat and spark plug threads may be reused without reducing service life, provided cracks do not exceed 0.5 mm (0.020 in.) width, or when no more than first threads are cracked.
When installing replacement cylinder head with camshaft installed, contact surfaces between valve lifters and cam lobe surfaces must be oiled after installing cylinder head.
When replacing cylinder head or head gasket, replace all coolant.
Checking compression pressures Page 15-7




--------------------------------------------------------------------------------

15-2


1 - Cylinder head gasket
Always replace
Ensure correct installation position: "OBEN" marking or part number must face cylinder head
Instlall gasket over centering pins in cylinder block
2 - 20 Nm (15 ft lb)
3 - Gasket
Always replace
4 - Cylinder head
Checking for distortion Fig. 1
Resurfacing dimensions Fig. 2
Installing Page 15-6
Servicing valve train Page 15-9
5 - 65 Nm (48 ft lb)
6 - Cylinder head bolts
Always replace
Follow installation instructions and sequence when loosening and tightening Page 15-6
7 - Heat shield
8 - 65 Nm (48 ft lb)




--------------------------------------------------------------------------------

15-3


9 - 10 Nm (7 ft lb)
Tighten diagonally
10 - Gasket
Flanged surface must face exhaust manifold
11 - 25 Nm (18 ft lb)
Always replace
12 - Exhaust manifold
With turbocharger
13 - 10 Nm (7 ft lb)
14 - Spring with bracket
15 - 10 Nm (7 ft lb)
16 - Cover
With ignition coils
17 - Gasket
Only replace if damaged
Insert in groove in cover
18 - Not applicable
19 - 10 Nm (7 ft lb)
20 - 10 Nm (7 ft lb)




--------------------------------------------------------------------------------

15-4


21 - Bracket
For vacuum hoses
22 - Cylinder head cover
23 - Gasket for cylinder head cover
Only replace if damaged
Insert in groove on cylinder head cover
24 - Plugs
Only replace if damaged
25 - Intake manifold
Use Allen socket VAG 1669 to remove and install
26 - Bolt
For oil dipstick guide tube
10 Nm (7 ft lb)
27 - Gasket
Always replace
28 - O-ring
Always replace
29 - Coolant pipe
30 - 10 Nm (7 ft lb)




--------------------------------------------------------------------------------

15-5


Fig. 1 Checking cylinder head for distortion
- Measure with feeler gauge at several locations.
Distortion: max. 0.1 mm (0.004 in.)

Fig. 2 Resurfacing cylinder head

Resurfacing of the cylinder head (grinding flat) is permissible up to minimum dimension -a- (measured through bolt hole).

Dimension -a- (minimum) = 118.1 mm (4.650 in.)




--------------------------------------------------------------------------------

15-6


Cylinder head, installing

Note:

Always replace cylinder head bolts.

There must be no oil or coolant in the blind cylinder head bolt holes in the cylinder block.

- Before installing cylinder head, set crankshaft and camshaft in cylinder head to Top Dead Center (TDC) for cylinder 1.

- Fit cylinder head gasket over centering pins: "OBEN" or part number must face cylinder head (watch hole pattern).

- Install cylinder head and cylinder head bolts; tighten by hand.

- Tighten cylinder head bolts in total of three stages - for sequence, see diagram.

Tightening torques (engine cold):

Stage I:
40 Nm
(30 ft lb)

Stage II:
60 Nm
(44 ft lb)

Stage III:
1/2 turn (180) further with rigid spanner without stopping

(2 x 90 is also permissible)


Note: Loosen cylinder head bolts in reverse order.
Additional retightening of bolts is not required.





--------------------------------------------------------------------------------

15-7


Compression pressure, checking

Engine warm-coolant temperature gauge at approx. 80C (176F).

- Turn quick fasteners (arrows) on connector cover on rear engine compartment bulkhead 90 to left and remove cover.

- Mark and separate connectors -5- and -6- (to ignition coils).
- Remove cover with coils on cylinder head cover Page 15-3 .
- Unscrew all spark plugs with spark plug wrench 3122 A.
- Check compression pressure with compression pressure recorder VAG 1381 and adapter 1381/1.
Throttle valve fully open
- Operate starter until no further pressure increase is indicated by tester.




--------------------------------------------------------------------------------

15-8


Compression pressures

Specified value: 9.0-13.0 bar (131-189 psi)
Wear limit: 7.0 bar (102 psi)
Maximum permissiblepressure difference betweenindividualcylinders: 3.0 bar (44 psi)

.......NExt subject:

Fig. 11 Removing and installing vibration damper

Tightening torque

With spanner 2079:
350 Nm
(258 ft lb)

Without spanner 2079:
450 Nm
(332 ft lb)

- Use brace 3256.
- Coat threads and contact surfaces of bolt head with sealing paste AMV 188 001 02.

Note:

Spanner 2079 for vibration damper must align with torque wrench.


Email me if you need some pictures..

Hope you can read this btw.

Cheers
Josh

[audiman]

Cylinder heads with cracks between valve seats or between valve seat and spark plug threads may be reused without reducing service life, provided cracks do not exceed 0.5 mm (0.020 in.) width, or when no more than first threads are cracked.


********, dont fit a head with a crack. It will not last. You can get the head welded up. Nice one Audi, i wonder if this was written by their mechanics and not the factory!!!

[Josh-stateside]

I forgot some info:



Note becarefully of some of the tighening torques bently mentions.

Ex: they state 15ft pounds for the idle pulley on the aby/aan motors. But that's way too much. I actually broke the bolt.

Just use your best judgement on any bolt smaller than 8mm.

Cheers
Josh

[Glen Chamberlain]

heads off!

Well its come off! The head is on the bench with both manifolds and turbo still attached. But how sick was i too see that it already had a metal gasket fitted!! But i suppose iam fitting peace of mind now? The head came of much easer than i expected! not nessasarily easy but easier! I'll take some piccs tomorrow @ work and post them with the others!
Theres not really an "how to" as such, but just unbolt the head and remove what needs to be removed! follow your nose really?

[Josh-stateside]

That's a 3b motor btw.

You can tell cause the water pump can be adjusted.

No comment on this design from audi, but I am certainly glad they changed that.

[Mark Halligan]

Nice info Josh, going to be doing this soon.

Thanks,

Mark.

[desmo888]

Originally posted by Josh-stateside
That's a 3b motor btw.

You can tell cause the water pump can be adjusted.

No comment on this design from audi, but I am certainly glad they changed that.

Use some vaseline in the o-ring for the waterpump. This will allow the o-ring to slide easily during adjustment and let it seal well.
Don't let this project itimidate you! You're doing fine. Just take your time and enjoy it. Don't get too anxious, get the timing belt slack just right.
I'll be rebuilding a 3B soon so any tips would be appreciated.
You may want to check my timing belt change instructions on www.20v.org
I've done a few.

Dave K.
'90 CQ - soon to be turbo powered...

[Josh-stateside]

That's another person's motor btw.
Also on the Es2 list: Ben from canada.

My motor has alllready made it's way into the engine bay

[desmo888]

Originally posted by Josh-stateside
That's another person's motor btw.
Also on the Es2 list: Ben from canada.

My motor has alllready made it's way into the engine bay

That Klumper Hoser, I know him. He's been a huge help in getting me started.

[porkkis]

Originally posted by audiman
Cylinder heads with cracks between valve seats or between valve seat and spark plug threads may be reused without reducing service life, provided cracks do not exceed 0.5 mm (0.020 in.) width, or when no more than first threads are cracked.


********, dont fit a head with a crack. It will not last. You can get the head welded up. Nice one Audi, i wonder if this was written by their mechanics and not the factory!!!

Mine has a crack and I'm going to put it back. It was pressure tested and no visual signs of any leaks were found.