Audi A3

since 1997 of release

Repair and car operation



Audi A3
+ Maintenance instruction
+ Current leaving and service
- Engine
   Compression check in engine cylinders
   Engine check by means of the vacuum gage
   Removal and installation of the bottom cover of an impellent compartment
   Removal and engine/RKPP installation
   + Four-cylinder petrol engines 1.6, 1.8 of l
   + Diesel engines
   + Major maintenance
   + greasing System
+ Systems of cooling, heating
+ the Power supply system and production of the fulfilled gases
+ engine Electric equipment
+ Manual box of gear shifting
+ Automatic transmission and models with a full drive
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Elektroskhema







Removal and engine/RKPP installation

GENERAL INFORMATION

Engine of 1.8 l

The engine together with RKPP acts in film down. Removal of the engine/RKPP block needs the crane. At all do not remove the engine/RKPP block by means of the garage lift since it can become the reason of heavy damages of the engine.

As on the bottom party of the car it is necessary to unscrew some connections, four supports, and for a car raising the lift are required. Before engine installation wings in an impellent compartment should be protected by covers.

Depending on year of release of the car and its equipment electric wires, and also vacuum hoses and hoses of system of cooling can have various laying. As here it is not obviously possible to describe laying of all possible options, it is recommended to mark the respective lines before a rassoyedineniye.

Necessary special tool and auxiliary material:

– Crane
– A clip for spring collars, for example, HAZET 798–5
– Load-lifting suspension bracket, for example, AUDI 2024 A
– MoS2 greasing, for example, AUDI G 000 100
– A Dinamometrichesky key on 5 … 50 N • m
– A Dinamometrichesky key on 40 … 200 N • m
– Cable connector

REMOVAL


ATTENTION

Cable connectors which act in film or cut at removal of the engine should be established on the former places. For this purpose it is necessary to mark places of their installation. For undocking of connections it is necessary to press stoppers and to pull for the tip.


PERFORMANCE ORDER
1. Disconnect a negative cable (–) the storage battery at the switched-off ignition.

ATTENTION

Thereof information from electronic blocks of memory, such as, a radio receiver code is erased. Without a code the radio receiver can be included only by the manufacturer or HUNDRED AUDIS. Therefore familiarize with instructions in subsection Input of a code of a radio receiver.


2. Remove the storage battery, address to the subsection Removal and installation of the storage battery.
3. Unscrew bolts of fastening and take out the holder of the storage battery.
4. Remove the actuator, address to the subsection Check, removal and installation of the traction relay of a starter.
5. Remove the case of the air filter, address to the subsection Removal and installation of the case of the air filter.
6. Unscrew bolts of fastening and remove an air pipe to the air filter on a bumper.
7. Remove the bottom cover of an impellent compartment, address to the subsection Removal and installation of the bottom cover of an impellent compartment.
8. Remove the right power shaft, address to the subsection Removal and installation of power shafts.
9. Disconnect the left power shaft from a flange of RKPP and adhere a wire to the stabilizer or the bottom.
10. Merge cooling liquid, address to subsection Replacement of cooling liquid.
11. Engine of 150 h.p.: Remove connecting pipes between турбокомпрессором / a radiator of forced air, турбокомпрессором / the air filter and a radiator of forced air / the inlet pipeline. For this purpose remove collars from hoses.
12. Weaken a tension of a maple belt and remove it, address to the subsections Removal and installation of a ridge maple belt and Removal and installation of a maple belt.
13. Unscrew bolts of fastening and remove the pump of the hydraulic booster from the holder, adhere it a wire to a body. Hoses do not disconnect.

ATTENTION

Hoses do not press. If the system at removal was opened, it is necessary to remove air from it, address to the subsection Removal and installation of the pump of the power steering.


Cars with the conditioner:

ATTENTION

Contour of cooling of the conditioner do not open. Hit of cooling liquid on skin can cause frostbite.
Unscrew collars of fastening of system of cooling of the conditioner. Do not braid, do not press and do not bend pipelines and conditioner hoses.


14. Unscrew bolts of fastening of the compressor (And) and (In) and adhere the compressor a wire to the lock of a cowl so that not to pull hoses.
15. Remove a reception pipe of the exhaust silencer and the catalytic converter, address to the subsection Removal and installation of system of release.
16. Disconnect a cable of a drive of gas, a stopper do not delete, address to subsection Adjustment of a drive of gas.
17. Uncover the engine at inlet the pipeline.
18. Rasstykuyte shtekerny connections of-1-coils of ignition and–3–injectors. Disconnect a negative cable–2–. On soprovoditelno illustration the engine of 150 h.p. is shown.
19. Disconnect the vacuum pipeline-4-on a pressure regulator.
20. Disconnect at the engine and a turbokompressor (h.p. engines 150 and 180) vacuum and soaking-up hoses. If necessary put on hoses and connecting unions of marking to exclude a mistake at assembly.
21. Rasstykuyte all shtekerny connections from the engine and RKPP to a body.

ATTENTION

The fuel system is under pressure! Before opening of shlangovy accessions cover them with a thick rag. After that carefully remove pressure. Use goggles. Danger of defeat by splashes!


22. Disconnect pipelines of giving–1–and return–2–at the fuel distributor for what compress release buttons on the coupling. Mark hoses a tape for simplification of the subsequent assembly.
23. Close топливопроводы a film and rubber rings to exclude hit in dirt system.
24. Disconnect 2 hoses of cooling liquid to the heater heat exchanger at a forward wall of an impellent compartment for what open collars.
25. Remove all hoses of cooling liquid from the engine to the top part and to a broad tank for what open collars and remove hoses.
26. Remove the fan with the holder, address to the subsection Removal and radiator and fan installation.
27. Cars with RKPP: Remove drives of switching and the coupling cylinder.

ATTENTION

After removal of the working cylinder of a drive of coupling do not press a coupling pedal.


28. Cars with AT: Unscrew bolts of fastening and remove the holder of the pressure head pipeline of the hydraulic booster at a box support. Remove a selector cable at a check point, address to subsection Adjustment of a cable of the selector of switching of automatic transmission.
29. Unscrew bolts of fastening of a pendular support below between a body and the block an engine/transmission.
30. Raise the car. It should be at distance not less and = 60 mm from the earth.
31. Put on the earth wooden whetstone (shooter) in the sizes 40 x 30 of cm and thickness of 15 cm for engine installation on it around the case pallet.
32. Connect the load-lifting AUDI-2024A device to a hook 3180 with eyes on the engine. Connect the vertical punched tires to openings 1 and 5 cross-section tires. Insert from an engine flywheel a finger into the second opening of the tire, from a pulley in the third opening. Openings are considered from a hook.

ATTENTION

Apply on hooks and fixing pins lock pins. For coordination with the unit center of gravity the punched tires should be correctly exposed on length.


33. If the corresponding load-lifting device available is not present, it is possible to apply a chain to unit lifting.
34. Raise the block an engine/transmission the crane so that to unload engine support.
35. Unscrew from above the right support of an engine/box.
36. Unscrew bolts of fastening of a support of a box at the left
37. Check, that all hoses and the pipelines going from the engine and a box to the chassis were disconnected.
38. Pull the block an engine/box forward as far as it probably and slowly lower on wooden laying. Carry out operation carefully not to damage mechanisms.

ATTENTION

Fix the block that it did not overturn.


39. If necessary, disconnect a box from the engine, address to the subsection Removal and RKPP installation.
INSTALLATION
40. Check existence of a time and cracks in rubber support of the engine and hoses of cooling, oil and fuel. If it is necessary, replace.
41. Only, if the engine was disconnected from a box: Check coupling. Insert fastening bolts an engine/box and tighten them the established moment of an inhaling. Thus be guided by instructions in the subsection Removal and RKPP installation.
42. Establish into place the block an engine/box and fix by hand new bolts.
43. Fix the pendular lever by hand new bolts.
44. Expose the block an engine/box strong rockings it hands.
45. Fix support of an engine/box and the pendular lever according to the values of torques given in Specifications. Thus all bolts at first tighten a dinamometrichesky key and then tighten bolts a rigid key on a corner 90 ° (1/4 turns).

ATTENTION

Bolts at an inhaling receive residual lengthening. Therefore after each inhaling it is necessary to apply new bolts.
Before an inhaling measure diameter of a carving of a bolt since the inhaling moment depends on it.


46. If the conditioner compressor acted in film, fix it the moment of 45 N of m.
47. Fix the power steering pump, address to the subsection Removal and installation of the pump of the power steering.
48. Establish a starter, address to the subsection Removal and starter installation.
49. Put on maple a belt and pull it, address to the subsections Removal and installation of a ridge maple belt and Removal and installation of a maple belt.
50. Fix an air pipe to the air filter at the holder of the lock.
51. Establish the case of the air filter, address to the subsection Removal and installation of the case of the air filter.
52. Engine of 150 h.p.: Establish connecting pipes between турбокомпрессором / a radiator of forced air, турбокомпрессором / the air filter and a radiator of forced air / the inlet pipeline. Fix hoses collars.
53. Establish a reception pipe of the exhaust silencer / the catalytic converter with new consolidations, address to the subsection Removal and installation of system of release.
54. Establish the left and right power shafts, address to the subsection Removal and installation of power shafts.
55. Attach a drive of gas and adjust it, address to subsection Adjustment of a drive of gas.
56. Put on a distributive pipe submitting and returnable топливопроводы. Quick disconnect couplings should be fixed distinctly.
57. Put on the hoses of a heater going from and to the heat exchanger at a forward wall of an impellent compartment. Fix them clips.
58. Establish the radiator fan with the holder, address to the subsection Removal and radiator and fan installation.
59. Cars with RKPP: Establish into place drives of switching and adjust them, address to subsection a gear shifting Drive.
60. Establish on RKPP the working hydrocylinder of a drive of coupling, address to the subsection Removal, installation and coupling check.
61. Cars with AT: Fix the holder of the pressure head pipeline of the hydraulic booster on a box support. Establish draft of the selector on a box and adjust it, to the subsection Removal, installation and coupling check.
62. Connect electric wires according to the markings put at removal and fix them.
63. Fix electric wires on places of their former fastening. Fix them collars.
64. Establish on a place and fix the holder of the storage battery.
65. Establish the battery, without attaching while a negative cable, address to the subsection Removal and installation of the storage battery.
66. Check, that electric wires, vacuum hoses, hoses of cooling and fuel hoses were connected according to their markings.
67. Check oil level in the engine and a transmission, if necessary fill in oil.
68. Check availability of antifreeze in cooling liquid and if necessary add, address to subsections Replacement of cooling liquid and Check of levels of liquids, control of leaks.
69. Establish an engine cover on the inlet pipeline.
70. Establish the bottom cover of an impellent compartment, address to the subsection Removal and installation of the bottom cover of an impellent compartment.
71. Attach a weight cable (–) the storage battery.

ATTENTION

Make active high-rise automatic equipment of an electric window regulator, and also establish hours and enter a radio tape recorder code, address to subsection Input of a code of a radio receiver.


72. Start and warm up the engine to working temperature. Check level of oil and cooling liquid. Check tightness of all shlangovy connections.
73. Check adjustment of headlights, address to subsection Adjustment of light of headlights.

ATTENTION

When undocking various electric connections in monitors malfunctions which after installation should leave register. As the electronic tester which joins the diagnostic socket of the car for this purpose is required. For this purpose it is necessary to address on HUNDRED.