Genuine 1992 Audi 100 Cylinder Head

1992 Audi 100 Cylinder Head Parts and Q&A

• Q: What are the steps involved in the removal and refitting process of the cylinder head for 5-cylinder petrol engines on 1992 Audi 100?

  A: The start of the process involves disconnection of the negative lead of the battery and also the separation of the engine top cover and the undershield in the engine compartment, and Jacking up of the front of the car may be required. Then remove the auxiliary drivebelt, undo the nuts to un-attach the exhaust downpipe to the exhaust manifold and hold the downpipe and retrieve the gasket. Take off exhaust manifold of the cylinder head draining the cooling system in advance. Unplug the accelerator cable and cruise control connection when required then unscrew the inlet manifold, the HT leads and the spark plugs, then the distributor. Unbolt the timing belt rear cover, removing the timing belt off the camshaft sprocket, taking care not to rotate the crankshaft or camshaft, removing the camshaft sprocket and tensioner and removing the timing belt. Then take out the camshaft cover, brake vacuum pump and plunger, making sure the plunger is removed to reveal one of the cylinder head bolts. In case of dismantling the cylinder head, then camshaft and tappets may be removed. Locate and detach all the fuel and vacuum hoses, wiring that impacts the removal of the cylinder head. The cylinder head bolts are loosened in the reverse order and then the cylinder head is removed by lifting it off the block tapping it as needed. To refit, clean the top of the block and install a new gasket on the top with the part number or TOP marking on the gasket face up. Wipe the face of the cylinder head, fit guide rods, place the gasket, fit the cylinder head on the block, and connect the bolts and the washers without jointing compound. Install the bolts in order, and with the correct torque and re-attach all the wiring and hoses. In such a case, remove, refit the camshaft and tappets, then the camshaft cover, timing belt rear cover, camshaft sprocket, and tensioner. Stretch the timing belt followed by re-fitting the distributor, spark plugs, HT leads, brake vacuum pump and inlet manifold. Reconnect the accelerator cable, the cruise control linkage, refill the cooling system, and lastly reconnect the exhaust manifold with a new gasket, tighten the nuts/bolts, reconnect the auxiliary drivebelt and lastly, reconnect the battery negative lead.