Detailed photo report about, how to replace the timing belt (timing) and valve stem seals (MSK) by car Audi A100 / S4 with a 2.2 l engine.
Spare parts used during the repair:
- _ Oil scraper cap_, VAG number 027109675 20 pieces;
- _ Timing chain_, VAG number 077109120;
- _ Timing Belt_, VAG number 054109119Н;
- _ V-ribbed belt_, VAG number 054903137B;
- _ Timing roller_, VAG number 078109244F;
- _ Poly V-belt roller_, VAG number 059145276;
- _Bearing viscous coupling of the fan_, VAG number 077115136A;
- _Camshaft oil seal_, VAG number 068103085E;
- _Crankshaft oil seal_, VAG number 054115147B;
- _ Valve cover gasket_, VAG number 034198025F;
- _Pump_, VAG number 054121004AX;
- _Pump gasket_, VAG number 035121043;
- _Camshaft bolt_, VAG number N90256202;
- _Crankshaft bolt_, VAG number 034105229A;
- _Crankshaft gear_, VAG number 034105263A.
And in the video you can also see how to cope with replacing the timing belt on an Audi 100 with a 2.3 AAR engine.
Pulling towards ourselves, remove the short and long grilles in the bumper.
We unscrew the self-tapping screws for attaching the “cilia” under the headlights, remove the cilia.
With a 13 head, unscrew the two bumper mounting bolts under the headlights.
With a 13 head, unscrew the two bumper mounting bolts from below.
Gently pull the bumper towards you, freeing the side bumper mounts, remove the bumper. We snap off the outside air temperature sensor from the bumper. Unscrew the four screws securing the side plastic covers of the radiator, remove the covers.
We unscrew the self-tapping screws of the upper mounts, remove the mounts.
We unscrew the fastenings of the “cilia” of the headlights on the right and left, remove the fasteners.
We unscrew the nuts of the radiator silent blocks on the right.
We do a similar procedure on the left.
We unscrew the screws securing the air intake to the radiator.
We take the right side of the radiator forward and fix it in this position.
The original uses a special mount 3251.
We unscrew the eight screws that secure the top panel and four screws that secure the headlights. Remove the top panel and set it aside. The bonnet cable fasteners do not need to be unscrewed in order not to adjust the bonnet opening later. Thus, further actions to replace the timing belt occur without depressurization of the air conditioning and cooling system..
We unscrew the four bolts securing the fan to the viscous coupling, remove the fan.
We unscrew the bolt securing the poly V-belt casing, remove the casing.
With an open-end wrench, we compress the spring of the tensioner of the poly V-belt, insert the stopper into the hole.
Unscrew the three tensioner mounting bolts, remove the tensioner.
Then remove the V-ribbed belt.
With an open-end wrench for 27, we lock the pulley of the power steering pump, unscrew the three bolts of the pulley.
After that, remove the pulley itself.
Using a special stopper, we fix the crankshaft pulley.
Using a powerful knob with a head of 27, loosen the center bolt of the crankshaft pulley. The tightening torque is very high and the bolt also sits on the glue, so using a stopper and a strong knob is a must. We also loosen the camshaft gear mounting bolt.
Without removing the pulley stopper, loosen the four bolts securing the pulley to the crankshaft gear.
Crankshaft pulley bolts.
To make it easier to turn the timing, we unscrew the spark plugs. Unscrew the three screws of the ignition coil cover, remove the cover with the coils.
After removing the lid – unscrew the candles.
Scrolling the timing for the crankshaft pulley, we combine the marks: 1) on the crankshaft pulley;
2) on the camshaft flywheel;
3) on the camshaft gear.
We unscrew the three bolts securing the timing belt tensioner, having previously loosened the tensioner roller mounting bolt to replace it. Then remove the tensioner.
Remove the crankshaft pulley with the gear.
Unscrew the two bolts securing the lower timing belt cover, remove the cover, remove the timing belt.
Carefully inspect the gear for key integrity.
If the key is in poor condition and practically torn off, then it is better to replace the gear with a new one.
While everything is disassembled and it is convenient to crawl, it is possible to wash the engine.
Using a thin chisel, we strike the viscous coupling nut by unscrewing it counterclockwise.
Then we remove the viscous coupling.
We unscrew the three bolts of the viscous coupling pulley, remove the pulley.
We unscrew the three bolts of the viscous coupling bearing, remove the bearing with the shaft.
We unscrew the bolt of the viscous coupling bearing.
We press out the viscous coupling bearing.
Press in the new bearing with a suitable head.
We loosen the clamp of the radiator pipe, remove the pipe.
We unscrew the bolts of the power steering pump.
Power steering pump mounting bolt.
We unscrew the three bolts securing the pump.
We move the power steering pump and take out the pump.
We put a new pump, do not forget the gasket.
We screw in place the bracket for the power steering pump.
Scratch out the crankshaft oil seal with a thin screwdriver.
We press the new crankshaft oil seal with a mandrel suitable for the diameter, after having liberally lubricated the oil seal with oil.
We unscrew the bolt of the camshaft gear to the end (we look at the same so that the marks do not go astray), remove the gear.
We carefully inspect the camshaft gear for the integrity of the key and the camshaft for the integrity of the keyway.
To change the camshaft oil seal, you need to remove the valve cover. After removing the cover, we proceed to replace the valve stem seals. First, we loosen the clamps..
After loosening the clamps, remove the ventilation pipes.
We unscrew the eight bolts securing the valve cover.
Remove the valve cover.
Checking the marks on the camshaft gears.
The marks must be opposite each other on the plane of the cylinder head.
Checking the inter-shaft chain play.
We proceed to unscrew the exhaust camshaft oil seal cover.
Then, as the cover was unscrewed – remove the oil seal.
Unscrew the front intake shaft cover.
We unscrew the camshaft covers. At the prom, first 2 and 4 caps, then 1, 3, 5.
At the inlet shaft, first covers 7 and 9, then 6, 8, 10.
Loosen the nuts alternately diagonally. The covers are numbered, so you won’t be able to mix them up during installation.
Removing the camshafts.
We take out the hydraulic lifters from the wells. It is advisable to put the wetsuit in the same places where they were taken from, but if they are mixed up, then it’s okay.
In order to dry the valves, it is necessary to block them somehow. We do this: we put the first cylinder in the position of the bottom dead center (BDC), take a clothesline and use a sharpened steel knitting needle to put the rope into the cylinder, it enters about 2.5-3 meters.
Next, we turn the crankshaft (temporarily put the crankshaft gear and pulley in place, tightening with bolts, but not tightening), raise the piston until we feel resistance – then the rope in the cylinder is compressed.
Now you can dry the valves, they will rest against the rope in the cylinder. The drying process is simple: you need to press on the valve plate and remove the “crackers” with tweezers or a magnetic screwdriver. When working with crackers, it is necessary to take measures to prevent them from falling into the secluded corners of the cylinder head – close the holes in the cylinder head with a clean rag.
After removing the “crackers”, we take out the upper plate, large and small valve springs, and we see in the depths the valve stem.
Use a collet puller to remove the valve stem seal.
Old caps tend to thicken and fit very tightly.
In order not to damage the edge of the new valve stem seal when installed on the valve, you need to use a special plastic cap, it usually comes with valve stem seals.
Liberally lubricate the valve stem seal with oil, put it on the valve and using a metal tube with an inner diameter of 12 mm. (you can use a pipe wrench for 12) push the cap and press it in until it stops.
Then we put the springs, the upper plate in place, press the decanter on the plate and insert the “crackers”, fixing them in the valve groove. The work is rather delicate, there is little space, you can use two thin long tweezers for this: with straight tips and curved ones. Rearrange the desiccant to replace the MSC inlet valves and repeat the procedure.
After replacing the MSC on all four cylinder valves, we turn the crankshaft, lowering the piston to BDC, and remove the rope from the cylinder. We repeat the entire procedure for the remaining cylinders. To replace the MSC in the fifth cylinder, we put the desiccant like this.
We put on the chain so that the marks on the camshaft gears are opposite each other.
Before screwing on the camshafts, install the crankshaft according to the above marks, the first piston at TDC. We fasten and tighten the camshaft covers: at the outlet, first caps 1, 3, 5, then 2 and 4; at the inlet shaft, first covers 6, 8, 10, then 7 and 9. Tighten the nuts to the required torque alternately diagonally. To install the camshaft oil seal cover, apply a little sealant in the indicated places.
We put on a new oil seal on the camshaft, but not all the way, after having abundantly greased the working edges of the oil seal with oil, put on the oil seal cover, slightly tighten the nuts.
With the help of a suitable mandrel, we push the oil seal until it stops and tighten the nuts.
Intake shaft front cover can be screwed on without sealant.
We put on a new gasket on the valve cover.
The gasket includes two semicircular seals.
Insert the gaskets into the grooves in the back of the cylinder head.
We apply sealant to the joints of the seals in the rear and front of the cylinder head according to the figure.
Rear part of the cylinder head.
Front part of the cylinder head.
We put on the valve cover, tighten it with the necessary moment, fasten the ventilation hoses.
We put the timing gear on the camshaft, the marks as we see in place, tighten the gear bolt, preventing the camshafts from turning. It is recommended to install a new bolt.
We remove the crankshaft pulley from the gear, put on a new timing belt, fasten the lower belt cover. We fasten the gear to the removed pulley.
Please note that there is a protrusion on the gear, and a groove on the pulley for this protrusion, they must be combined.
We put a pulley with a gear on the crankshaft.
Apply a locking compound to the central bolt of the crankshaft, tighten and tighten the bolt, preventing the crankshaft from turning.
Screw on the viscous pulley.
Also, do not forget to screw the viscous coupling itself.
We fasten the timing belt tensioner with a new roller, do not tighten the tensioner bolts so that it can move freely in the grooves.
We put on the timing belt on the pump and the camshaft gear so that the side of the belt passing through the pump does not have slack and is not weakened.
With a key or a 22 head, turn the tension roller housing clockwise, thereby tightening the timing belt.
Tighten the tensioner bolts.
The tension on the belt should be such that you can turn the belt 90 degrees with two fingers, as shown in the figure.
We look at the coincidence of the marks, turn the crankshaft by the central bolt a few turns, look at the coincidence of the marks and the tension of the timing belt. If the marks match and the belt is not loosened, then move on. If the belt is loose or the marks have “parted”, then it is necessary to loosen the tensioner, remove the belt from the camshaft gear, re-set the marks and repeat the 3 previous steps. We put a stopper on the crankshaft pulley, rest it on the beam and tighten the central bolt of the crankshaft.
Without removing the stopper, tighten the four bolts of the crankshaft pulley.
Without removing the stopper, tighten the camshaft gear bolt.
We put on the upper timing belt cover, fix it with latches.
We dress and tighten the power steering pump pulley.
We change the tensioner pulley of the poly V-belt. In the absence of a vice, it can be fixed with two bolts on its bracket with the roller up.
Remove the cap.
Unscrew the roller mounting bolt.
We change the roller to a new one, tighten the roller bolt, put the tensioner in place.
We put on the V-ribbed belt as shown in the figure.
Using an open-end wrench, loosen the tensioner and remove the stopper, while the belt is tightened. With the poly V-belt tensioned, tighten the viscous coupling nut, fasten the fan to the viscous coupling. Putting the “muzzle” in the reverse order, screw in the candles, put the cover with the ignition coils.
repair manual Audi 100 IV (C4)