Audi A3

since 1997 of release

Repair and car operation



Audi A3
+ Maintenance instruction
+ Current leaving and service
+ Engine
+ Systems of cooling, heating
+ the Power supply system and production of the fulfilled gases
+ engine Electric equipment
- Manual box of gear shifting
   Removal and RKPP installation
   Gear shifting drive
   Removal and installation of the case of the mechanism of a choice of transfers
   Adjustment of a drive of switching
+ 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 RKPP installation

GENERAL INFORMATION

For removal the car should be lifted on necessary height. Besides, the corresponding garage lift is necessary for lowering of a box. Here process of removal of RKPP of engines of 1.8 l with a forward drive is in detail described. Remarks on RKPP removal for engines of 1.6 l, and also removal of AT are provided in the Section end.

Engines of 1.8 l

REMOVAL

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

Thereof information from electronic blocks of memory, as, for example, 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 materials of the subsection Check and replacement of brushes of the generator and a tension regulator.


2. Remove a fan casing.
3. Rasstykuyte I will corrode the sensor of a tachometer–1–, and also the switch of back foggy lamps–2–.
4. Unscrew bolts of fastening and disconnect a damper and a cable of a drive of switching of RKPP (In).
5. Disconnect a cable of a drive of a choice of transfers from the directing lever (C) for what raise a pad in the arrow direction.
6. Disconnect a hose of the working cylinder at a cable support. Unscrew bolts of fastening and disconnect a cable support on RKPP (are specified by shooters) and take aside.
7. Unscrew 2 bolts of fastening and disconnect the working cylinder from RKPP and fix with the attached hydraulic pipeline on one side bodies.
ATTENTION

The hydraulic pipeline do not disconnect, otherwise after installation of hydrosystem it is necessary to remove from it air. At the removed cylinder do not press a coupling pedal.


8. Disconnect a weight wire from the top bolt of-1-connections the RKPP/engine. Turn out a bolt–1–.
9. Disconnect the holder of a cable–3–above at a starter (the shooter on an illustration) and take aside.
10. Unscrew a bolt–2–above at a starter.
11. Turn out all bolts of fastening available from above between the engine and RKPP.
12. Will hang out the engine. For this purpose establish the adaptation, for example, to AUDI 10-222A in a combination to support 10-222A/1.
13. Slightly raise the power unit by means of screws.
14. If the specified adaptation available is not present, put over an impellent compartment a pipe and sideways обоприте it on wooden whetstones. Do not put a pipe on wings. Hook for engine eyes on cables and connect to the screw. Pull a cable.
ATTENTION

When lifting and car installation on supports there is a danger! Therefore previously familiarize with car Poddomkrachivaniye's subsection.


15. Lift and establish the car on supports. Remove the bottom cover of an impellent compartment, thus address to the subsection Removal and installation of the bottom cover of an impellent compartment.
16. Remove a starter.
17. Unscrew bolts of fastening and remove the holder of a wire of a drive of the hydraulic booster at RKPP case.
18. Remove, if is available, a protective cover of the right flange of a power shaft (And)
19. Unscrew a fastening bolt (the top arrow) small cover behind the right power shaft and uncover.
20. Unscrew bolts of fastening of power shafts and disconnect, thus address to the subsection Removal and installation of power shafts.
21. Suspend on a wire as it is possible above power shafts for what turn a steering wheel to the left against the stop.
ATTENTION

Do not damage thus a paint and varnish covering.


22. Separate release system between the catalytic converter and the central exhaust silencer, thus address to subsection Replacement of the central/additional exhaust silencer.
23. Unscrew bolts of fastening and disconnect a pendular support between a body and engine/RKPP side (an arrow on an illustration).
24. Unscrew bolts of fastening and disconnect a bar of a support of RKPP at the left (an arrow A on an illustration), then disconnect RKPP support (an arrow B on an illustration).
25. Unscrew bolts of fastening of a support of RKPP (And) on a box and disconnect. To take out fastening bolts (are specified by shooters), lower the block dvigatel-RKPP by means of spindles so that bolts were available from the left wheel arch.

ATTENTION

When lowering the unit watch to damaging power steering pipelines.


26. Fix the special tool (C) a bolt (In) at fastening of a pendular support from below. Insert the adaptation for an extraction (And) and fix bolts (are specified by shooters). Wring out the block dvigatel-RKPP forward.

ATTENTION

If the special tool available is not present, the block dvigatel-RKPP can be shifted forward by an onboard jack. Thus watch to damaging power steering pipelines.


27. Slightly raise RKPP the lift, for example, AUDI 3282. Previously arms of support of RKPP are exposed on a yustirovochny plate 3282/8. If the RKPP lift is not present available, raise RKPP a garage jack.

ATTENTION

Lay between RKPP and a jack wooden laying.


28. Turn out the bottom bolts of fastening between the engine and RKPP.
29. Wring out RKPP from directing plugs and carefully put forward.
ATTENTION

At съеме RKPP watch to damaging the pipeline of the hydraulic booster.


INSTALLATION
ATTENTION

If RKPP is replaced, rearrange the speedometer sensor, the lever of inclusion of transfers and the switching lever from old RKPP on the new.


30. Before installation of coupling check it, thus address to the subsection Removal, installation and coupling check.
31. Clear and slightly grease primary shaft of RKPP with MoS2 or AUDI-G 000 100 greasing.
ATTENTION

The disk of coupling should move easily on a shaft.


32. Check, whether directing plugs for an engine/RKPP block centering are established in the block of cylinders. If necessary insert.
33. Wring out the lever of switching off of coupling before RKPP installation to a case of RKPP and fix by means of an assembly bolt or bolt М8 x 35. After installation a bolt turn out.
34. Raise RKPP and enter its coupling. If thus primary shaft of RKPP does not enter into a coupling disk, turn hands primary shaft behind for a flange. At installation watch the correct provision of an intermediate plate.
35. Turn and take out the special tool or a jack.
36. Screw bolts of fastening of RKPP and a starter. For this purpose establish a starter.
37. Screw bolts of fastening of the engine/RKPP block as far as possible deeply.
38. Again turn out bolt М8 x 35 for fixing of the lever of switching off of coupling on a coupling casing. The opening is closed by a bolt of fastening of a support of draft of a drive.
39. Fix by hand the left holder at RKPP and establish in the engine/RKPP assembly situation by means of the crane.
40. Tighten by hand engine/RKPP support new bolts (In).
41. Tighten by hand a pendular support new bolts.
42. Clean the elevating device for the engine and RKPP.
43. Level the engine/RKPP block, having strongly shaken it in different directions.
44. Tighten the engine/RKPP block and a pendular support according to the values given in Specifications. Thus bolts tighten at first a dinamometrichesky key and then tighten a rigid key on a corner 90 ° (1/4 turns).
ATTENTION

Bolts at an inhaling receive residual deformation. Therefore after each otvorachivaniye new bolts are applied.


45. Establish power shafts, thus address to the subsection Removal and installation of power shafts.
46. Establish big and small covers of power shafts.
47. Establish the left bolts of fastening of the holder of the engine and fix the moment of 50 N of m (on an illustration - an arrangement and the moments of a tightening of bolts of fastening of a transmission).
48. Establish a starter.
49. Fix bolts a cable support the moment of 25 N of m to RKPP.
50. Fix a cable of switching the moment of 25 N of m to the gear shifting lever.
51. Connect a cable of a drive of a choice to the switching lever.
52. Fix a counterbalance on the gear shifting lever. Tighten fastening bolts at first a dinamometrichesky key the moment of 20 N of m and then tighten a rigid key on a corner 90 ° (1/4 turns).
53. Adjust a gear shifting drive, address to subsection Adjustment of a drive of switching.
54. Fix the socket at RKPP, thus address to the subsection "Removal".
55. Join the socket at a starter.
56. Grease the end of a rod of the working cylinder of a hydraulic actuator with MoS2 greasing. Insert into place the working cylinder and fix it the moment of 20 N of m
57. Several times press a pedal of coupling and check work.
ATTENTION

If the hydraulic actuator opened, remove from system air.


58. Establish a reception pipe / the catalytic converter with new sealing laying, thus address to the subsection Removal and installation of system of release.
59. Fix the holder of the pipeline of the power steering on RKPP case, thus address to the subsection Removal and installation of the pump of the power steering.
60. Check oil level in RKPP, thus address to subsection Check of level of the RKPP transmission oil.
61. Establish the bottom cover of an impellent compartment, thus address to the subsection Removal and installation of the bottom cover of an impellent compartment.
62. Establish the case of the air filter, thus address to the subsection Removal and installation of the case of the air filter.
63. Attach a negative cable (–) to a battery battery room.
ATTENTION

Make active automatic equipment of safety of electric window regulators, enter a radio receiver code, establish hours, thus address to subsection Input of a code of a radio receiver.


Specially for engines of 1.6 l
ATTENTION

The description of works and the remarks concerning all with RKPP, are provided in subsection for engines of 1.8 l. In the real subsection the differences relating only to the engine of 1.6 l are described only. These differences concern, first of all, a drive of switching which for the engine of 1.6 l occurs through drafts, and at other engines through cables.


64. Will hang out the engine by means of the crane, having hooked on the engine for eyes on a head of cylinders.
65. Disconnect by means of a screw-driver forward draft–1–from the lever-2-. Remove a lock washer–3–, remove the console-4-.
66. Disconnect the console-4-turn on 90 ° (1/4 turns) to the right from draft with a damper – 5–. Reject draft with a damper up and remove from a bearing-6-support.
67. Disconnect by means of a screw-driver long connecting drafts from the lever of a choice of transfers (are specified by shooters). Unscrew a bolt and disconnect the forward lever of switching–1–at RKPP.
68. Turn out bolts–2–and remove the console of switching–3–with connecting drafts and the switching lever
69. Disconnect a hose of the working cylinder at a support. Unscrew 2 bolts of fastening and disconnect the working cylinder (are specified by shooters) at RKPP and fix with the attached hose to a body a wire.

ATTENTION

Do not disconnect the hydraulic pipeline, otherwise it is necessary to delete air from coupling after its installation. After removal of the working cylinder it is impossible to press a coupling pedal.
After RKPP installation it is necessary to make adjustment of a drive of switching, thus address to subsection Dismantling of a shaft of a drive.