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Audi  Engine Information

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The following technical bulletins were published by AERA.


                                                            Lack of Compression For
                                                       1998-2001 Audi 2.8L 5V Engines

The AERA Technical Committee offers the following information regarding lack of compression on 1998-2001 2.8L 5V Audi engines. Complaints for this condition include poor performance, hard starting or no start conditions. The cause of this condition may be carbon build-up on any of the engines thirty valves preventing it from sealing. 

Several measures are now available from Audi to resolve and help prevent reoccurrence of this condition. They include installing a hotter thermostat and performing an approved carbon cleaning process. At this time, only Wynn's X-Tend® V.I.C. Combustion Chamber Cleaner: Part No: 61510 (U.S.), Part No: 61512 (Canada) is authorized for use by Audi. 

A revised (hotter) thermostat was developed and installed in engines beginning after VIN 8DXA279411 for A4 vehicles and after VIN 4BXN116771 for A6 vehicles. The thermostat operating opening temperature increased from 87°C to 92°C. 

Engines should also be checked to verify the coolant temperature sending unit must be later than week 19 of 1998, i.e. 19/98. This will be stamped into the side of the sensor housing (arrow) as shown in Figure 1. Replace the sensor if necessary.
  Figure 1.

Note: Customers should be made aware that this type of carbon build-up may be due to fuels that do not contain a sufficient blend of detergents. Customers should be given the brochure Facts about Carbon and Fuel Quality (Literature No. W425527100) and advised to use Autobahn Gasoline Additive (ZVW 239 003), which is very effective in reducing and preventing carbon buildup, even if the fuel used does not contain a sufficient blend of detergents.

Audi also recommends installing a new set of spark plugs. Install new spark plugs Part #101000067 AA (NGK BKR6EQUPA) and a set of six 4-hole injectors, Part #078133551BA. The injector can be identified by their RED color as shown by the arrow in Figure 2.
   Figure 2. Four Hole Injector

It will also be necessary to change engine oil after carbon removal treatment and it is Important to note: DO NOT use 20W 50-engine oil - use ONLY factory-approved oil with proper viscosity.  

                                                                       The AERA Technical Committee


                     Revised Flywheel Bolts And Torque Specifications On 
                            Audi 2.0L (3A), 2.2L (3B), 2.3L (7A, NG) Engines

Audi has revised the flywheel bolts on 1988-91 2.0L (3A), 2.2L (3B), 2.3L (7A, NG) engines used in the Audi 80, 90, 90 Coupe and 200.  

The revised bolt, Part # N 902 061 03, features a shoulder and uses the torque-to-yield method to achieve its final clamping load.  Seat the bolts using a torque of 22 lbs.ft., then turn each bolt an additional 1/4 turn, or 90o.  Because of their
special locking compound coating, the revised flywheel bolts may only be used once.

The former bolt, Part # N 902 061 01, which was torqued to 74 lbs.ft., did not have a shoulder and is no longer being serviced.

For additional information see AERA Technical Bulletin: TB-821

                                                                       The AERA Technical Committee


                                         Cylinder Head Installation On
                                            Audi 5000 Diesel Engines

After being sure the cylinder head and engine block mating surfaces are thoroughly clean, install the cylinder head gasket DRY.  NO SEALING COMPOUND SHOULD BE USED.

Install the cylinder head and torque the cylinder bolts in the sequence shown in three steps as follows:

     1st Torque to 50 N·m (35 ft. lbs.)
     2nd Torque to 70 N·m (50 ft. lbs.)
     3rd Torque to 90 N·m (65 ft. lbs.)

Start the engine and run it to operating temperature.  The cooling fan should cycle on.

Stop the engine and retorque the bolts to 90 N·m (65 ft. lbs.) without backing off.

After about 1000 miles of operation, retorque the head bolts again.  With the engine hot or cold, follow the same sequence as above and loosen each head bolt (one at a time) 30° and retorque it again to 90 N·m (65 ft. lbs.).

                                                                           The AERA Technical Committee


                                          Interference Engines

The AERA Technical Committee would like to offer the following information on engines that present the possibility of interference between pistons and valves. The interference or contact may bend valve(s) when the timing between the camshaft and crankshaft is interrupted. This is generally the result of a timing belt or chain breaking or slipping.

The following list are engines that AERA is currently aware of that have exhibited interference. There may be other engines that are not listed below that have the possibility of piston to valve contact. If the engine you are working on is not listed, do not assume that it is a freewheeling design. It is suggested to add to this listing as additional information is obtained.

1986-89 1.6L Integra
1991-95 1.7L Integra
1990-95 1.8L Integra 
1986-89 2.5L Legend
1992-94 2.5L Vigor
1986-89 2.7L Legend
1990      2.7L Legend
1991-95 3.0L NSX
1991-95 3.2L Legend

1970-93 All Except 1970-77 
1.9L & 1970-73 1.8L

1987-95 2.5L 325I 525I
1994-95 4.0L 740I

1993-95 1.5L Colt 
1987-88 1.5L Colt	
1992-95 1.5L Eagle Summit
1987-88 1.6L Colt	
1989-92 1.6L Eagle Summit
1994-98 2.0L Neon Stratus
1990-95 2.0L Eagle Talon

1988-92 1.0L Charade
1988-92 1.3L Charade
1990-92 1.6L Rocky

1974-79 1.3L 128 Series
1979-82 1.5L Stranda
1974-78 1.6L 124 Series
1974-78 1.8L 124 Series
1974-78 1.8L 131 Series, Brava
1979-82 2.0L Brava, Spider 

1981-85 1.6L Escort, EXP
1981-83 1.6L LN7, Lynx
1984-85 2.0L Escort, Tempo
1993-95 2.0L Probe
1986-88 2.0L Ranger
1984-87 2.0L Lynx, Topaz Diesel
1985    2.2L Ranger
1989-92 2.2L Probe
1986-88 2.3L Ranger
1986-87 2.3L Diesel Ranger
1991-98 4.6L Crown Victoria

1986-95 1.0L Geo Metro
1989-91 1.0L Firefly (CANADA)
1985-88 1.5L Sunburst (CANADA)
1985-89 1.5L Spectrum
1990-93 1.6L Prizm, Storm
1981-84 1.8L Diesel (CANADA)
1982-86 1.8L Buick Skyhawk
1990-98 1.9L Saturn
1987-88 2.0L Buick Skyhawk
1988-95 2.3L Quad Four
1985-87 3.0L Buick
1979-95 3.8L Buick

1986-87 1.0L Prelude
1973-78 1.2L All
1973-78 1.3L All
1980-84 1.3L All
1973-78 1.5L All
1985-89 1.5L Civic
1988-95 1.5L Civic, CRX
1993-95 1.5L Civic Del Sol
1979-84 1.5L All
1985-87 1.5L CRX
1993-95 1.6L Civic Del Sol
1973-78 1.6L All
1980-82 1.6L All
1988-95 1.6L Civic, CRX
1984-87 1.8L Prelude, Accord
1979-83 1.8L All
1986-91 2.0L Prelude
1990-91 2.1L Prelude
1990-95 2.2L Prelude, Accord
1992-95 2.2L Prelude
1995      2.7L Accord

1984-95 1.5L Excel Scoupe
1995-98 1.5L Accent
1992-95 1.6L Elantra
1993-95 1.8L Elantra
1992-95 2.0L Sonata
1989-91 2.4L Sonata
1990-95 3.0L Sonata

1990-92 3.0L M30

1987-89 1.5L I-Mark
1990-93 1.6L Stylus Impulse
1987-89 2.0L Impulse
1981-87 2.2L Diesel Truck
1986-95 2.3L Truck Trooper
1988-95 2.6L Truck Rodeo Amigo
1991-96 3.2L Trooper Rodeo Amigo

1995      2.0L Sportage

1984-85 2.0L 626 
1988-92 2.2L 626 MX6
1989-93 2.2L Pickup
1988-95 3.0L 929 MPV

1985-95 1.5L Mirage Precise
1990-92 1.6L Mirage
1989-95 2.0L Galant Eclipse
1983-86 2.3L Diesel Pickup
1994-95 2.4L Galant

1982      1.5L Centra
1983-88 1.6L Sentra Pulsar
1987-89 1.8L Pulsar
1982-89 2.0L Stanza 300ZX
1984-95 3.0L Maxima 300ZX Pathfinder

1976-83 2.0L 924
1976-89 2.5L 944 Series
1989      2.7L 944 Series
1989-91 3.0L 944 Series
1976-83 4.5L 928
1984      4.7L 928
1985-91 5.0L 928
1992-95 5.4L 928

1985-94 1.3L Samurai Sidekick
1989-94 1.3L Swift

1986-95 1.5L Tercel
1981-83 2.2L Pickup
1984-87 2.4L Pickup
1982-88 2.8L Celica Cressida
1987-94 3.0L 4-Runner

1976-91 All Except 1.9 2.1L Engine
1990-92 1.6L Golf (CANADA) Jetta
1990-95 2.0L GTI Jetta GLI Passat

1991      2.3L Coupe 940
1986-94 2.3L 240 740 940 

                                                                              The AERA Technical Committee


                    Exhaust Manifold Leaks on
                 1984-85 Audi 5000 2.1L Engines

A warped exhaust manifold may cause exhaust gas leaks at the
cylinder head on 1984-85 Audi 5000 2.1L engines.  The warped
exhaust manifold may also break the manifold studs at the #1 and
5 cylinder (see illustration below).  

This condition can be prevented by checking the manifold for
straightness and machining if necessary during remanufacture of
the engine.  Audi furthermore recommends that the exhaust
manifold studs at the #1 and 5 cylinder be replaced with tempered
studs, Part #901 889 02.  The appropriate nuts and washers carry
the part numbers 902 002 01 and 900 955 01 respectively.

                                     The AERA Technical Committee

June 1990 - TB 658


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