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
+ Automatic transmission and models with a full drive
- Coupling and power shafts
   - Coupling
      Removal, installation and coupling check
      Air removal from hydrosystem of a drive of coupling
   + Power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Elektroskhema







Removal, installation and coupling check

GENERAL INFORMATION

Bearing of switching off of coupling, RKPP case. Engines of 1.8 l

1–РКПП
2–spherical pin, 25 N • m
To cover with MoS2 greasing.
3–sealing ring of primary shaft of RKPP
Enter against the stop.
4–the directing plug
The sealing ring on the plug cannot be replaced separately. Around the bearing of switching off of coupling grease with MoS2 greasing.
5–lock spring
Fastens on the lever of the bearing of switching off of coupling.
6–bolt, 20 N • m
7–lever of the bearing of switching off of coupling
Around the bearing of switching off of coupling grease with MoS2 greasing.
8–bearing of switching off of coupling
The bearing not to wash out but only to wipe. If the bearing publishes noise at work, to replace.
9–bolt, 20 N • m
10-working cylinder
11-pusher
Grease the pusher end with MoS2 greasing.
12-assembly bolt
Fixes the lever of switching off of coupling at RKPP installation. After RKPP installation turn out.

ATTENTION

If the assembly bolt is not present, bolt М8 x 35 can be applied.


Bearing of switching off of coupling, RKPP case. Engines of 1.6 l

1–cover
Removal: Punch a sharp opravka and remove, having hooked.
Installation: Sealing surfaces should not contain some greasing. A new cover press on a circle the corresponding opravka.
2–bearing of switching off of coupling
It can be replaced without RKPP removal.
3–lever of switching off of coupling
Removal: Remove a lock bracket (5). Sideways take out a shaft (9).
The lever can be inserted only in one situation.
4–plug
5–lock bracket
6–needle bearing
7–plug
8–sealing ring
9–shaft of switching off of coupling
10-RKPP cover
11-a mouth stopper for oil filling, 25 N • m

Engines, except 1.6 l

(The description of works for engines of 1.6 l is provided below)

REMOVAL

PERFORMANCE ORDER
1. Remove RKPP, thus address to the subsection Removal and RKPP installation.
2. To exclude flywheel rotation at an otvorachivaniye of bolts of fastening, it is necessary to hold him the AUDI-3067 tool or a screw-driver and a core.

ATTENTION

The AUDI-3067 tool on an illustration is shown in the provision of installation. At removal it is necessary for overturning. Installation of coupling needs an aligning opravka of AUDI-3190А or a usual aligning core, for example, HAZET 2174.


3. Unscrew bolts of fastening of a press disk cross-wise everyone on 1-1, the 5th turn so that the disk was released.
ATTENTION

If bolts turn away at once, press springs can be damaged.


4. After easing bolts are turned out completely.
5. Take out press and conducted coupling disks.
ATTENTION

Do not drop press and conducted disks. Otherwise after assembly in work of coupling there can be breakthroughs and difficulties in switching off.


6. Wipe the bearing of switching off of coupling, without washing out it.
7. Wipe a flywheel a rag moistened in gasoline.
CHECK

At installation of the details which were in work of their coupling it is necessary to check previously.
8. Check press a disk on existence of places of an overheat and задиров.
9. Check press springs on existence of damages (are specified by shooters). Wear to a half of thickness of a spring is allowed.
10. Check connections of springs between a press disk and a cover on existence of cracks. Zaklepochnye connections check on durability. In the presence of weak connections or damages coupling replace.
11. Check an adjacent surface of a press disk on existence of cracks, overheat and wear places. In the presence of deformation of a press disk to 0.2 mm in it still it is possible to use. Check is carried out by a ruler and shchupy.
12. Check a flywheel on existence of cracks of an overheat and задиров.
13. The disk of coupling made oily or having mechanical damages replace with the new.
14. Check thickness of frictional overlays of a disk of coupling and existence of cracks in slips.
15. In conditions HUNDRED disk of coupling can be checked on palpation. Face palpation of a disk should not exceed 0.8 mm (2.5 mm measured at distance from edge).
ATTENTION

The specified check is necessary only in that case when the disk which was in work is established and there were shortcomings of its work. If necessary the disk can be careful отрихтован.


16. Check by hand the bearing of switching off of coupling in the established situation. For this purpose slightly compress the bearing and turn. The bearing should rotate easily. At work damage of the bearing of switching off of coupling is determined by noise at the pressed pedal of coupling. It is recommended to replace the bearing.
INSTALLATION
ATTENTION

If new details of coupling are established, it is necessary to check press a disk and a conducted disk according to the catalog of spare parts on their compliance to exclude erroneous installation.


17. Before installation of a new press disk it is necessary to remove a protective anticorrosive layer only on the working party. In other places greasing is not removed at all, otherwise it can lead to essential decrease in service life of coupling.
18. Check durability of fastening of aligning pins on a flywheel.
19. Clear shlitsa of a conducted disk of a rust. Grease with a thin layer of MoS2 greasing of a shlitsa of primary shaft of RKPP. HUNDRED applies to this AUDI G 000 100. After that move a conducted disk on a shaft, having checked ease of a course. Surplus of greasing surely remove.
20.
ATTENTION

At installation of a conducted disk watch that the separator of springs showed towards a press disk. If coupling with a two-mass flywheel is established, separators of springs are not present. In this case coupling is established so that the frictional slip adjoined to a flywheel. The nave should not adjoin at a flywheel, the short end of a nave shows towards a press disk.


21. Center a conducted disk on a press disk by means of a core, for example, HAZET 2174 or AUDI – 3176 (are specified by shooters). If the conducted disk is located not on the center, primary shaft cannot occupy the working situation. As an aligning core the old primary shaft of RKPP can be applied.
22. Establish press a disk on the corresponding aligning pins.
ATTENTION

Press the disk should adjoin completely to a flywheel and should not warp. Otherwise aligning pins and openings can be damaged. Only after that insert fastening bolts. At all do not pull together press a disk with bolts, aligning openings of a press disk and aligning pins on a flywheel differently can be damaged.


23. Screw bolts of fastening of a press disk and tighten them cross-wise, turning on 1 – 1.5 turns so that press the disk was fixed. Inhaling moment: 20 N of m.
ATTENTION

At execution with screws with an internal shestigrannik the last are tightened by the moment of 13 N of m.


24. Remove aligning core.
25. Establish RKPP, thus address to the subsection Removal and RKPP installation.
Engines of 1.6 l
REMOVAL
26. Remove RKPP, thus address to the subsection Removal and RKPP installation.
27. To exclude flywheel rotation at an otvorachivaniye of bolts of fastening, it is necessary to fix it the AUDI-558 tool or a screw-driver with an opravka.
ATTENTION

Mark the provision of a flywheel of rather press disk that it was possible to establish them in former situation. If the flywheel is established incorrectly, VMT marking on a flywheel loses the situation.


28. Unscrew bolts of fastening of a flywheel one by one on 1 – 1.5 turns.
ATTENTION

If bolts turn away at once, press springs can be damaged.


29. If bolts turn away at once, press springs can be damaged.
30. Take out a conducted disk.
ATTENTION

Do not drop press and conducted disks. Otherwise after assembly in work of coupling there can be breakthroughs and difficulties in switching off.


31. Hook a screw-driver and take out from openings (are specified by shooters) a lock ring (And) a disk of switching off of coupling (In).
32. Remove a disk of switching off of coupling (In).
33. Disconnect press a disk from a flywheel for what fix on a press disk the AUDI 558 tool a bolt (And). If the specified tool available is not present, press the disk can be held a screw-driver and an opravka.
34. Remove press a disk and an intermediate plate.
35. Wipe a flywheel a rag moistened in gasoline.
CHECK

At installation of the details which were in work of their coupling it is necessary to check previously.
36. Check zaklepochny connections on a press disk. A disk with the damaged or weakened zaklepochny connections replace with the new.
37. Check a frictional surface of a press disk on existence of cracks, overheat and wear places. In the presence of deformation of a press disk to 0.2 mm in it still it is possible to use. Check is carried out by a ruler and shchupy.
38. Wipe from oil frictional surfaces of a press disk and a flywheel.
39. A greasy or worn-out conducted disk replace with the new.
ATTENTION

Sign of the damaged bearing of switching off of coupling is noise by pressing a coupling pedal at movement. The bearing is located behind a cover from outer side of RKPP and can be replaced without RKPP removal.


INSTALLATION
ATTENTION

If new details of coupling are established, it is necessary to check press a disk and a conducted disk according to the catalog of spare parts on their compliance to exclude erroneous installation.


40. Before installation of a new press disk it is necessary to remove a protective anticorrosive layer only on the adjacent and frictional party. In other places greasing is not removed at all, otherwise it can lead to essential decrease in service life of coupling.
41. Establish press a disk with an intermediate plate on a cranked shaft.

ATTENTION

Watch the provision of installation of an intermediate plate. The eminence (on an accompanying illustration) shows the shooter aside from a press disk. Screw new bolts of fastening and block press a disk as at removal by the AUDI-556 tool or a screw-driver and an opravka.


42. Fix press a disk a dinamometrichesky key the moment of 60 N of m and then tighten bolts a rigid key on a corner 90 ° (1/4 turns).
ATTENTION

Bolts at an inhaling receive residual deformation therefore after each otvorachivaniye it is necessary to replace them with the new.


43. Insert a disk of switching off of coupling and fix a lock ring on a press disk. Insert both ends of a wire into openings of a press disk.
44. Clear shlitsa of a conducted disk of a rust. Grease with a thin layer of MoS2 greasing of a shlitsa of primary shaft of RKPP. HUNDRED applies to this AUDIG 000 100. After that move a conducted disk on a shaft, having checked ease of a course. Surplus of greasing surely remove.
45. Check durability of fastening of aligning pins on a flywheel. If any pin on a flywheel sits not strongly, it is necessary to replace it.
46. Check durability of fastening of aligning pins on a flywheel. If any pin on a flywheel sits not strongly, it is necessary to replace it.

ATTENTION

If the flywheel is established incorrectly, VMT marking on it occupies incorrect situation.
The flywheel should adjoin to a press disk of coupling completely. Only after that fastening bolts are inserted.
Do not warp a flywheel since pins and aligning openings otherwise can be damaged. At all do not draw a basket of coupling by bolts since pins and aligning openings otherwise can be damaged.


47. If the AUDI 3178 tool was applied, take out it.
48. Establish RKPP, thus address to the subsection Removal and RKPP installation.