2.0l 4-cyl Audi 80 B3

ENGINE CODING

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

ENGINE IDENTIFICATION

Engine identification number is stamped on a machined pad, left side of engine block, near distributor assembly. (Scheme 8) The first 2 characters designates the engine code.

ENGINE CODES

Engine Identification Number Location. Scheme 8

8-Valve Engines

E-I-E-I-I-E-I-E (Front-to-Rear).

16-Valve Engines

Right Side - Exhaust Valves.

Left Side - Intake Valves.

Note. "Right" and "Left" refer to right and left side of engine NOT vehicle.

ADJUSTING VALVE CLEARANCE

Note. Cylinder heads without shims between camshaft(s) and lifters are not adjustable. See LIFTERS under VALVES .

1. After any cylinder head repair, check and adjust valves with engine cold. After 1000 miles (after repair) or at normal service interval, adjust with engine warm. Shims are available in different thicknesses. Etched side of shim must be installed away from camshaft.
2. Position camshaft lobes of cylinder to be check with high points facing upward (valves closed). Measure clearance. See «VALVE ADJUSTMENT SPECIFICATIONS»(/audi/80/b3-1986-1991/remont/mechanical/#20l-4-cyl) table. If clearance cannot be achieved with thinnest shim, shorted valves may be installed. If clearance is greater than specifications, use appropriate shim to acquire proper clearance.
3. To remove shim, rotate lifter (follower) so grooves face inward towards each other (one cylinder at a time). Using Lifter Compressor (2078) and Pliers (10-208), remove shim. To install, reverse removal procedure.

VALVE ADJUSTMENT SPECIFICATIONS

ENGINE R & I

Note. Match mark engine mounts to ensure original alignment is achieved after installation. On vehicles with A/C and power steering, remove components with hoses attached and secure out of way.

Removal

1. Disconnect negative battery cable. Open heater valve, coolant expansion tank and drain radiator through lower radiator hose. Mark and disconnect all heater hoses. Disconnect electric cooling fan and thermo switch. Remove lower and side radiator mounting bolts. Remove fan, shroud and radiator. Remove M/T clutch cable and release cylinder (if equipped).
2. Mark and disconnect electrical wiring and vacuum hoses (as necessary). Disconnect throttle, cruise and kickdown linkage (if equipped). Remove fuel injectors and install protective caps and plugs. Leave fuel lines attached and remove cold start valve. Remove charcoal canister and set aside.
3. Remove 3 upper engine-to-transaxle bolts. Remove intake air duct. Remove left and right engine mount nuts. Disconnect and remove starter assembly. Remove 2 lower engine-to-transaxle bolts. Remove transaxle inspection cover plate. Disconnect exhaust inlet pipe support and separate inlet pipe from exhaust manifold.
4. Support transaxle. Attach engine sling to engine lifting hooks. Raise engine/transaxle until engine clears engine mounts. Ensure transaxle is supported. Remove remaining engine-to-transaxle bolts. Lift and separate engine from vehicle without transaxle.

Installation

Lubricate transaxle main shaft splines and contact area between clutch release bearing and clutch pressure plate with MoS2 grease. DO NOT lubricate guide sleeve for clutch release bearing. To complete installation, reverse removal procedure. DO NOT reuse self-locking nuts. Ensure engine mounts are installed to original location. Tighten engine mounts and subframe bolts with engine running at idle.

Engine/Transaxle Alignment. Scheme 9

No removal procedure available from manufacturer. Cylinder head may be removed with engine in vehicle. Match mark all components for installation reference. Timing belt must be removed. See TIMING BELT R & I. (Scheme 10)or (Scheme 11). Remove cylinder head bolts in reverse sequence of installation. (Scheme 12) Replace cylinder head bolts after loosening or removing.

Exploded View of 16-Valve Cylinder Head. Scheme 10

Exploded View of 8-Valve Cylinder Head. Scheme 11

Inspection

Thoroughly clean all gasket mating surfaces. Check cylinder head for warpage. The 8-valve cylinder head can be machined and 16-valve cylinder head cannot be machined. Check camshaft(s). See INSPECTION under CAMSHAFT R & I. See ENGINE SPECIFICATIONS tables.

Note. DO NOT reuse antifreeze after replacing cylinder block, cylinder head, head gasket, radiator and/or heater core.

1. Ensure marking on cylinder head gasket is properly positioned and install gasket on cylinder block. DO NOT use any type of sealant. Carefully position cylinder head on cylinder. Install head bolt Nos. 9 and 10 hand tight to ensure cylinder head position. Install remaining head bolts hand tight.
2. Tighten cylinder head bolts in sequence to specifications. See «TORQUE SPECIFICATIONS»(/audi/80/b3-1986-1991/remont/mechanical/#20l-4-cyl) table. No further information is available from manufacturer.

Cylinder Head Bolt Tightening Sequence. Scheme 12

Exploded View of Timing Belt Components. Scheme 13

Information not available from manufacturer. Use exploded view for component locations. (Scheme 13) Match mark all components to ensure reassembly to original position.

Scheme 14

Scheme 15

1. Align flywheel/flex plate "O" mark with pointer. This is TDC. Remove distributor cap and check position of ignition rotor. Rotate intermediate shaft and position rotor at No. one cylinder mark on housing. (Scheme 14) Install timing belt on crankshaft and intermediate sprockets. (Scheme 14): Aligning Ignition Rotor
2. With intermediate shaft/ignition rotor positioned, rotate crankshaft and align mark on crankshaft pulley with mark on intermediate shaft sprocket. Position camshaft sprocket mark even with valve cover surface. (Scheme 15) Install timing belt on camshaft sprocket. (Scheme 15): 8-Valve Timing Mark Alignment
3. Rotate tensioner clockwise to tighten belt and install lock nut. Proper tension is achieved when belt can be twisted 90 degrees. (Scheme 16) Rotate crankshaft 2 revolutions and check timing mark alignment. To complete installation, reverse removal procedure.

Proper Timing Belt Tension. Scheme 16

Scheme 17

1. Install timing belt around crankshaft and intermediate shaft sprockets. Install lower timing belt cover. Install vibration damper, noting offset holes. If valve cover is installed, mark on front of camshaft sprocket must align with mark on valve cover. If valve cover is removed, place camshaft sprocket mark even with valve cover surface. (Scheme 17) (Scheme 17): 16-Valve Timing Mark Alignment
2. Align crankshaft sprocket mark with mark on lower timing belt cover. (Scheme 17) Install timing belt around camshaft sprocket. Rotate tensioner clockwise until Timing Belt Tension Scale (VW 210) reads 13-14. Rotate crankshaft 2 revolutions and check timing mark alignment. To complete installation, reverse removal procedure.

Removing Camshaft Oil Seal. Scheme 18

1. Remove upper timing belt cover. Place crankshaft at TDC with No. one cylinder on compression stroke. Remove timing belt from camshaft sprocket. Remove camshaft sprocket. Remove Woodruff key. Install camshaft sprocket bolt and washer until washer is tight against camshaft.
2. Rotate inner part of Oil Seal Extractor (2085) outward 2 turns and tighten set screw. (Scheme 18) Lubricate threaded area of extractor and push in as far as possible. Loosen set screw and turn inner part of extractor until oil seal is removed.

Coat new seal seat and lips lightly with engine oil. Using Installer (10-203), install seal until flush. On 16-valve engines, use Special Hex Head Bolt (10-203/1). To complete installation, reverse removal procedure.

CAMSHAFT

Removal (8-Valve)

1. Remove upper timing belt cover. (Scheme 13) Remove valve cover. Place crankshaft at TDC with No. one cylinder on compression stroke. Remove timing belt from camshaft sprocket. Remove camshaft sprocket. Remove Woodruff key.
2. Remove bearing cap Nos. 1, 3 and 5 evenly a little at a time. Repeat for remaining caps. Lift camshaft out of cylinder head. See INSPECTION under CAMSHAFT R & I.

On engines with oil spray jets, position spray at right angle to camshaft. Place camshaft in cylinder head with both high points of lobes, on No. one cylinder facing upward. Install bearing cap Nos. 1, 3 and 5. Tighten evenly a little at a time. Repeat procedure for remaining bearing caps. To complete installation, reverse removal procedure. Ensure timing marks are properly aligned. Allow lifters to bleed down for 30 minutes before starting engine.

1. Check camshaft end play with camshaft unloaded. Check camshaft run-out at center journal. If not within specifications, replace camshaft and/or cylinder head. Check camshaft bearing oil clearance. See «ENGINE SPECIFICATIONS»(/audi/80/b3-1986-1991/remont/mechanical/#20l-4-cyl) tables.
2. If oil clearance is greater than specifications, install new camshaft and recheck clearance. If clearance is still greater than specifications, replace cylinder head. If replacing camshaft(s), ensure identification number between lobes of cylinder one, are the same.

Scheme 19

1. Remove upper timing belt cover. (Scheme 13) Remove valve cover. Place crankshaft at TDC with No. one cylinder on compression stroke. Remove timing belt from camshaft sprocket. Remove camshaft sprocket. Remove Woodruff key. (Scheme 19): 16-Valve Camshaft Bearing Caps
2. Remove intake camshaft bearing cap Nos. 5, 7 and rear evenly a little at a time. (Scheme 19) Loosen remaining intake camshaft bearing caps evenly a little at a time. Remove exhaust camshaft bearing cap Nos. 1, 3, front and rear evenly a little at a time. Loosen remaining exhaust camshaft bearing caps evenly a little at a time. Remove loosened caps. Lift camshafts out of cylinder head together.

1. On engines with oil spray jets, position spray at right angle to camshaft. Place chain on both camshaft gears. Align marks on gears and place both camshafts in cylinder head as shown. (Scheme 20)
2. Install intake camshaft bearing cap Nos. 6 and 8 and tighten evenly a little at a time. (Scheme 19) Repeat procedure for remaining intake camshaft bearing caps. Install exhaust bearing cap Nos. 2 and 4 and tighten evenly a little at a time. Repeat procedure for remaining exhaust bearing caps. To complete installation, reverse removal procedure. Allow 30 minutes before starting engine for lifters to bleed down.

16-Valve Camshaft Gear Position. Scheme 20

Oil pan can be removed and installed with engine in vehicle. No further information available from manufacturer.

Removal & Installation

Remove flywheel/flex plate and discard retaining bolts. Oil seal may removed without removing retaining flange by prying seal out. Remove retaining flange if gasket is leaking. (Scheme 23) If installing without removing retaining flange, use Centering Tool (2003/2A) to center seal and Installer (2003/1) to install seal.

Remove timing belt. See TIMING BELT R & I. Rotate inner part of Oil Seal Extractor (2085) outward 2 turns and tighten set screw. (Scheme 18) Lubricate threaded area of extractor and push in as far as possible. Loosen set screw and turn inner part of extractor until oil seal is removed.

Lubricate outer edge and lip of new seal. Place guide sleeve from Seal Installer (3083) onto crankshaft. Push oil seal over guide sleeve. Press seal completely into position. To complete installation, reverse removal procedure.

INTERMEDIATE SHAFT ASSEMBLY R & I

Remove timing belt. See TIMING BELT R & I. Mark distributor assembly for installation reference and remove distributor assembly. Check intermediate shaft end play. Remove intermediate shaft sprocket. Remove intermediate shaft seal flange. Replace seal (if necessary). To install, reverse removal procedure. See ENGINE SPECIFICATIONS tables.

CRANKCASE CAPACITY

CRANKCASE CAPACITY

NORMAL OIL PRESSURE

Minimum oil pressure at idle is 4.3 psi (.3 kg/cm 2 ). Oil pressure at 2000 RPM is 29 psi (2.0 kg/cm 2 ).

Remove oil pan. Remove oil pump attaching bolts and remove oil pump assembly. To install, reverse removal procedure.

Check oil pump backlash and oil pump axial play. If not within specifications, replace oil pump assembly. See OIL PUMP SPECIFICATIONS table.

OIL PUMP SPECIFICATIONS

VALVE SEALS & SPRINGS SERVICE

Valve seals and springs may be removed with cylinder head installed in vehicle. Remove camshaft as previously described. Mark and remove lifters. Use compressed air to hold valves closed. Installation Bar (2036), Spring Compressor (VW 541/1) and Valve Seal Replacer/Sleeve (10-204/A) are necessary tools for replacing. DO NOT install valve seal without using sleeve.

Scheme 21

1. Check valve seats prior to any other cylinder head service. If valve seats are less than specifications, cylinder head must be replaced. Insert the valve and hold firmly against the valve seat. Measure distance of valve stem tip to valve cover mounting surface. (Scheme 21) (Scheme 21): Measuring For Refacing Dimension
2. Subtract measured distance from minimum specifications. See «MINIMUM VALVE-TO-CYLINDER HEAD DIMENSION»(/audi/80/b3-1986-1991/remont/mechanical/#20l-4-cyl) table in this article. The total is maximum refacing allowable for both valve and seat. If more is required, replace cylinder head assembly. If less than minimum dimension is used, valve lifters will not function.

MINIMUM VALVE-TO-CYLINDER HEAD DIMENSION

VALVES SERVICE

1. With valves removed, measure dimension of valves. If not within specifications, replace valves. DO NOT reface exhaust valves with machine. Lap valves by hand or replace them as necessary. See «ENGINE SPECIFICATIONS»(/audi/80/b3-1986-1991/remont/mechanical/#20l-4-cyl) tables. CAUTION: On 16-valve engines, exhaust valves are sodium filled. Use following procedure to dispose of valves properly.
2. To dispose of sodium filled valves, cut valve stem off near head of valve with hacksaw. DO NOT allow water to contact valve during cutting. Throw valve stem in bucket of water and move quickly away. Once reaction with water has ceased, discard valve. Repeat procedure as necessary.

VALVE GUIDES SERVICE

If valve-to-guide clearance is not within specifications, replace guide(s). See ENGINE SPECIFICATIONS tables. To replace valve guide, press guide out from combustion chamber side. Press guide in cold cylinder head as far as guide will go. DO NOT exceed 1 ton pressure. Ream guides by hand to achieve proper valve-to-guide clearance.

LIFTERS SERVICE

1. If equipped with hydraulic lifters, no adjustment is possible. If lifter noise is present, start engine and allow to warm until cooling fan engages. Increase engine speed to 2500 RPM for 2 minutes. If lifter noise is intermittent or continues, replace necessary lifters.
2. To determine weak or noisy lifter, position camshaft so No. 1 cylinder lobes high point faces upward. Using a piece of wood, push down on lifter. If lifter can be pushed down more than .004" (.10 mm), replace lifter. Repeat procedure for remaining lifters (as necessary).

DO NOT measure cylinder block while mounted on an engine stand. Inaccurate measurements may be achieved. Check cylinder bore for wear, out-of-round and taper. Pistons are available in oversize. Cylinder block bore may be machined. Check cylinder block for warpage. See ENGINE SPECIFICATIONS tables at end of this article.

PISTON & ROD ASSEMBLY SERVICE

Ensure piston, rod and rod caps are marked with matching cylinder number prior to removal. Ensure engine front arrow is marked on top of piston. (Scheme 22) Pistons and rods are to be replaced in sets of 4. Rod cap bolts and nuts must be replaced after removing or loosening.

Piston, Rod & Rings. Scheme 22

Ensure piston and rod are properly marked. Remove both circlips from pin bore groove. Use Piston Pin Replacer (VW 207C) to remove and install the piston pin. If pin is too tight, heat piston to 140°F (60°C). To install, reverse removal procedure. Ensure rod is properly positioned with piston. (Scheme 22)

FITTING PISTONS

DO NOT measure clearances with cylinder block mounted on an engine stand. Check clearance of piston-to-cylinder bore. Piston diameter is stamped on top of piston in millimeters. Arrow on top of piston faces front of engine.

PISTON-TO-CYLINDER BORE DIMENSIONS

FITTING RINGS

Measure ring end gap. Measure ring side clearance with piston. If not within specifications, replace as necessary. See ENGINE SPECIFICATIONS tables at end of this article. Install rings on piston with "TOP" mark facing upward. Recessed edge on outside of center ring must face piston pin (down). Position ring ends as shown. (Scheme 22)

Exploded View of Crankshaft Assembly. Scheme 23

MAIN BEARINGS SERVICE

Main bearing caps are marked with matching journal and must be installed to original position. (Scheme 23) Thrust bearing is located at No. 3 main bearing cap. Use Plastigage method to check clearance. Machine or replace as necessary. See ENGINE SPECIFICATIONS tables. Tighten evenly to specifications in several steps.

CONNECTING ROD BEARINGS SERVICE

Ensure rod caps are marked to ensure installation to original position and location. Use Plastigage method to measure bearing clearances. Measure connecting rod side play. Replace or machine as necessary. See ENGINE SPECIFICATIONS tables. Tighten evenly to specifications in several steps.

CRANKSHAFT END PLAY

Insert feeler gauge between No. 3 main bearing and crankshaft thrust face to measure end play. (Scheme 23) Replace thrust bearing as necessary. See ENGINE SPECIFICATIONS tables. Original thrust bearing uses plain shell with 4 separate washers and replacements have attached collar.

WATER PUMP R & I

1. Disconnect negative battery cable. Turn heater control to hot. Drain cooling system by disconnecting lower radiator hose at thermostat housing. Remove accessories and brackets (as necessary).
2. Mark and remove coolant hoses from water pump. Remove water pump pulley. Remove bolts and remove water pump assembly. To install, reverse removal procedure. Remove thermo time switch, located on water flange prior to filling cooling system.

Note. For further information on cooling systems, see ENGINE COOLING article in this section.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

VALVE SPECIFICATIONS

Information is not available.

PISTON/PIN/RING SPECIFICATIONS

Information is not available.

BEARING SPECIFICATIONS

Information is not available.

CAMSHAFT SPECIFICATIONS

Information is not available.

WARPAGE SPECIFICATIONS

WARPAGE SPECIFICATIONS

See also:
• VALVES
• VALVE ADJUSTMENT SPECIFICATIONS