Audi A4 with 2001- 2005 of release.
1. Operation and car maintenance service
2. The engine
2.1. The general data
2.2. Predvaritlnye checks
2.3. A Mehanichsky part (petrol engines 2,0л)
2.3.1. Engine removal
2.3.2. Removal and installation semi wedge a belt
2.3.3. Removal and installation of a belt pulley crankshaftа
2.3.4. Removal and installation of a gear belt
2.3.5. Removal and installation of a sealing flange and a flywheel / a conducted disk
2.3.6. Replacement манжетного consolidations crankshaftа on the party of a belt pulley
2.3.7. Removal and installation of a forward sealing flange
2.3.8. Removal and installation of a two-mass flywheel
2.3.9. Removal and installation of a conducted disk
2.3.10. Removal and installation of a cranked shaft
2.3.11. Removal and запрессовка the needle bearing in crankshaft
2.3.12. Removal and asterisk installation
2.3.13. Dismantling and assemblage of pistons and rods
2.3.14. A head of the block of cylinders
2.3.15. Removal and installation of the valve of 1 system of change of phases timing
2.3.16. Removal and installation of a cover of a head of the block of cylinders
2.3.17. Removal of a head of the block of cylinders
2.3.18. Installation of a head of the block of cylinders
2.3.19. Compression check
2.3.20. Repair клапанного the mechanism
2.3.21. Removal and phase shifter installation
2.3.22. Removal and installation of cam-shafts
2.3.23. Replacement маслосъемных caps (at the established head of the block of cylinders)
2.3.24. Check of directing plugs of valves
2.3.25. Replacement манжетного consolidations of a final cam-shaft
2.4. Greasing system
2.5. Cooling system
2.6. Injection system
2.7. System of release of the fulfilled gases
2.8. A mechanical part (petrol engines 3,0; 3,2)
2.9. A mechanical part (petrol engines 4,2)
2.10. A mechanical part (diesel engines 2,0)
2.11. Tables
3. Transmission
4. A running gear
5. The steering mechanism
6. Brake system
7. An onboard electric equipment
8. A body
9. Electric equipment schemes
 




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2.3.1. Engine removal

THE NOTE
The engine acts in film forward at the removed framework of a radiator.
At становке again establish on former places all fixing elements of the cables which removed or have been cut off during dismantling.
For recycling or a reuse cooling liquid should be merged in pure capacity.

Operating procedure
In cars with АКПП establish the selector in position źN╗.

Fig. 2.43. Mass cable АКБ


Disconnect a mass cable from АКБ at the switched off ignition (fig. 2.43).

ATTENTION
At opening the broad tank can leave hot steam or a hot cooling liquid, wrap up a cover rags and cautiously open a tank.

Open a cover of a broad tank of system of cooling.
Remove forward wheels.

Fig. 2.44. Bolts of an exhaust pipe of an independent additional heater


In cars with an additional heater unscrew bolts of an exhaust pipe of an independent additional heater from шумоизоляционного the screen (fig. 2.44).

Fig. 2.45. Fastening of a forward noise isolation


Loosen the quick disconnect муфты 1 and 2 also remove a forward noise isolation (fig. 2.45).
Where are available, loosen the quick disconnect муфты 3 and remove back шумоизоляционный the screen.

Fig. 2.46. The holder шумоизоляционного the crane


Turn off the holder шумоизоляционного the screen (fig. 2.46).
Establish a casing of a forward bumper.

Fig. 2.47. An air pipe left интеркулера


Remove air pipes right and left интеркулеров (fig. 2.47).
Substitute the pallet for service cranes or the pallet under the engine.

Fig. 2.48. A drain bolt on a water hose


Open a drain bolt on a water hose from below at the left and merge ОЖ (fig. 2.48).

Fig. 2.49. A collar of the bottom hose of system of cooling


Remove the bottom hose of system of cooling from a radiator (fig. 2.49).

Fig. 2.50. An air line hose to интеркулеру and an arm of the pipeline with a coolant


Disconnect a hose of an air line 1 to интеркулеру at the left below (fig. 2.50).

ATTENTION
It is forbidden to open a contour of a central air of climatic installation.

Disconnect the pipeline with a coolant from an arm 2.
Disconnect вохдуховод 1 to турбонагнетателю on the right below.

Fig. 2.51. Air lines to интеркулеру and to турбонагнетателю


Disconnect an air line 2 to интеркулеру from a radiator framework (fig. 2.51).

Fig. 2.52. Пережатие hoses of a coil of a drive of the hydraulic booster


Press hoses to a cooling coil of a drive of the hydraulic booster by means of clips for hoses (fig. 2.52).
Put the adaptation for откачки oils.
Disconnect hydrodrive hoses.

Cars with an automatic transmission
Put the adaptation for откачки oils under a transmission.

Fig. 2.53. Tubes ATF and an arm of highways for ATF on the engine


Disconnect tubes for ATF 2 and 3 on a division place (fig. 2.53).
Turn off fastening of an arm of 1 highways for ATF on the engine.

All cars

Fig. 2.54. An engine casing


Remove an engine casing (fig. 2.54).
Unscrew bolts.

Fig. 2.2. An air line


Remove an air line 1 and 2 (fig. 2.2).
Remove the top hose of system of cooling 1 from a radiator.

Fig. 2.55. The top hose of system of cooling and electric штекерное connection of the left and right gauges of pillows of safety on a radiator framework


Disconnect electric штекерное connection of 2 left and right gauges of pillows of safety on a radiator framework (fig. 2.55).

Fig. 2.56. Electric штекерное headlight connection


Disconnect electric штекерное connection of headlights on the left and right parties of the car (fig. 2.56).

Fig. 2.57. Electric sockets


Remove electric sockets 1 and 2 from the holder and disconnect (fig. 2.57).
Will put electric cables aside.

Fig. 2.58. Shtekernye sockets of sound signals


Disconnect at the left and on the right штекерные sockets of 3 sound signals 2 (fig. 2.58).

THE NOTE
Poses. 1 in attention do not accept.

Remove a bumper.

Fig. 2.59. Bumper protection



Fig. 2.60. Fastening of the left air line


Turn off fastening of air lines at the left and on the right on a radiator (fig. 2.60).
Take the gauge of external temperature 2 of the holder.

Fig. 2.61. The gauge of external temperature and a cooling coil of a drive of the hydraulic booster


Unscrew bolts 3 and 4 and remove cooling coil of a drive of the hydraulic booster (fig. 2.61).
Disconnect electric штекерное connection 1 on the high pressure gauge.

ATTENTION
It is forbidden to open a contour of a central air of climatic installation.

Unscrew fixing bolts of the condenser.

THE NOTE
To avoid condenser damages, and also pipelines and hoses of a contour of a central air, it is necessary to watch that lines and hoses have been laid without a tightness, excesses and breaks.

Turn the condenser with the connected highways downwards.
Unscrew bolts at the left and on the right on a radiator framework.
Disconnect тросовый a drive from the cowl lock.

Fig. 2.62. Fastening of a sealant of a motor compartment on a radiator framework


Remove a sealant of a motor compartment on a framework of a radiator and on connecting edges of wings (fig. 2.62).

Fig. 2.63. Fastening энергопоглащающего buffers


Unscrew bolts at the left and on the right from энергопоглащающего buffers (fig. 2.63).

THE NOTE
The assistant is necessary for removal of a framework of a radiator.

Remove a framework of a radiator and put in steady position.

THE NOTE
Before removal semi wedge a belt mark a direction of a course with a chalk or a felt-tip pen. Change of a direction of a course before a maintained belt can lead to its damage


Fig. 2.64. Easing semi wedge a belt


For easing semi wedge a belt turn tension damper in an arrow direction (fig. 2.64).
Fix a tension element by means of a clamp.
Remove поликлиновый a belt.

Fig. 2.65. An electric socket of the gauge of level and oil temperature


Disconnect an electric socket from the gauge of level and oil temperature (fig. 2.65).

Fig. 2.66. An arm of a tube of a contour of a central air


Remove an arm of a tube of a contour of a central air from the oil pallet (fig. 2.66).

Fig. 2.67. Fastening of the compressor of the conditioner and штекерный a wire socket


Disconnect штекерный a socket of 1 wire going to electromagnetic муфте of the compressor of the conditioner (fig. 2.67).

ATTENTION
It is forbidden to open a contour of a central air of climatic installation.

Turn off the compressor of the conditioner from an arm.

THE NOTE
To avoid condenser damages, and also pipelines and hoses of a contour of a central air, it is necessary watch that lines and hoses have been laid without a tightness, excesses and breaks.

Will hang out the compressor of the conditioner and the condenser with the connected pipelines on the right on a body.
Disconnect a wire of weight 1.
Disconnect the vacuum tube going to the amplifier of brakes, from a motor board 2.

Fig. 2.68. A weight wire, a motor guard and an absorber hose


Disconnect a hose of an absorber 3 (fig. 2.68).

Fig. 2.69. Water hoses and fastening of a broad tank of system of cooling


Disconnect water hoses 1 and 2 and turn off fastening of a broad tank of system of cooling (fig. 2.69).
Disconnect штекерный a socket going to the gauge of a signalling device of low level ОЖ below on a broad tank of system of cooling.
Disconnect an electric socket from the gauge of pressure of pressurisation 1.

Fig. 2.70. An electric socket of the gauge of pressure of pressurisation and the left hose наддувочного air


Disconnect the left hose for наддувочного air 2 (fig. 2.70).

Fig. 2.71. The right hose наддувочного air


Disconnect the right hose for наддувочного air 1 (fig. 2.71).
Disconnect electric sockets of 1 ljambda-probe after the catalyst and a heater of a ljambda-probe 1 after the catalyst (a brown socket) from an arm.

Fig. 2.72. Electric sockets of ljambda-probes


Disconnect electric sockets of 2 ljambda-probe and a ljambda-probe heater (a black socket) from an arm (fig. 2.72).

ATTENTION
Pressure of fuel should be removed before opening of any knot of a high pressure.


Fig. 2.73. The connecting union топливопровода


Disconnect топливопровод (following fuel collect and immediately close all open apertures) (fig. 2.73).
Disconnect behind on the engine the water hoses going to the heat exchanger of a heater.
Remove screen wiper levers.
Remove дефлектор.

Fig. 2.74. A cover of the switching block


Uncover the switching block in a water taking away box, having turned off screws (fig. 2.74).

Fig. 2.75. Fastening of levers


Levers fix коромыслом with the help трещетки (fig. 2.75).
Turn off an electric cable 1.

Fig. 2.76. An electric cable and sockets in the switching block


Disconnect electric sockets 2.4 in the switching block (fig. 2.76).

Fig. 2.77. An unblocking of the block of safety locks


Unblock the block of safety locks (fig. 2.77).
Release a plait of wires and put it with the connected block of management of the engine on the engine.

Fig. 2.78. Boltovye connections of the lamellar pump


Turn off болтовые connections of 1 lamellar pump through apertures in a pulley for semi wedge a belt (fig. 2.78).

Fig. 2.79. Carving connection on the back party of the lamellar pump


Turn off carving connection on the back party of the lamellar pump (fig. 2.79).
Disconnect electric sockets 1 and 2 and release a cable.

Fig. 2.80. An inlet hose of the air filter / turbocharger and electric sockets


Disconnect an inlet hose 3 air filters / turbocharger (fig. 2.80).

Fig. 2.81. An electric socket of a flowmeter of air


Disconnect an electric socket 1 from air flowmeter (fig. 2.81).
Release a plait of wires on the case of the air filter and remove the case.

Fig. 2.82. Fastening of a mass wire


Turn off a mass wire from the right longeron (fig. 2.82).

Fig. 2.83. The heat-shielding screen right карданного a shaft


Turn off the heat-shielding screen 1 right карданного a shaft (fig. 2.83).

THE NOTE
The demountable element of system of release cannot be bent more than on 10 ░.


Fig. 2.84. Tightening a collar


Loosen the tightening a collar also shift back (fig. 2.84).
Separate a reception pipe and the catalyst.

Fig. 2.85. A reception pipe of the catalyst


Turn off a bolt 1 on an arm of a reception pipe and remove a pipe (fig. 2.85).

Fig. 2.86. An electric socket of the switch of lanterns of a backing


Disconnect an electric socket from the switch of lanterns of a backing and release a cable of a plait of wires (fig. 2.86).

Fig. 2.87. Carving connections of the engine / of a check point


Turn off carving connections of the engine / of a check point accessible from below 1–3 and 7–11 (fig. 2.87).
Remove a starter and shift aside.
Disconnect штекерное connection 3.
Turn off a nut of 1 collar.

Fig. 2.88. Starter removal


Turn off a nut 2 and remove electric wires (fig. 2.88).
Remove a starter.
Mark adjusting position of connections of 1 and fixing plugs 2 from below on the right and left pillows of the engine.

THE NOTE
Various fixing apertures are intended for various engines.


Fig. 2.89. Fastening of the right pillow of the engine


Unscrew nuts 1 from below the left and right pillows of the engine (fig. 2.89).

Fig. 2.90. Fastening of the left pillow of the engine


Loosen the on some turns the top nut on the left pillow of the engine (fig. 2.90).

Fig. 2.91. Posting of the power unit


Suspend the adaptation for posting for the engine and to the crane for service as it is represented in drawing 2.91.

THE NOTE
For alignment of position of the centre of gravity of the power unit of a lath of hooks should be inserted, as is shown in drawing 2.91.

ATTENTION
Hooks and lock pins of the adaptation for posting should be fixed pins.

Turn off last connecting bolt of the engine and a transmission.

THE NOTE
Check up, whether all hoses and wires between the engine and a body are separated.

Lift the engine so that hairpins of pillows of the engine were liberated.
Lift a jack to прилегания transmissions.
Separate the engine and a transmission and lift the engine forward from a motor compartment.

Engine installation

THE NOTE
At installation replace self-locking nuts and bolts/screws.
Replace the bolts/screws tightened on a certain corner, and also sealing rings, манжетные consolidations and sealing rings of round section.
Hoses and шланговый unions of system of pressurisation of air should be cleared before Ustanovkaom of oils and greasing.

For fastening of all connections of hoses use collars of a corresponding series.
At return Ustanovkae establish all cable couplers where they have been established initially.

Cars with a mechanical transmission
At installation of a new disk of coupling in connection with an old SAC-press disk of coupling (self-regulated press a disk) it is necessary to turn an adjusting ring of a press disk against the stop. Otherwise press the disk will work with the reduced pressure of a clip (coupling slips).

THE NOTE
If the coupling disk does not vary, it is not necessary to turn an adjusting ring.

New SAC-press disks are already preliminary adjusted and adjustment do not demand.
Gear gearing of a power shaft and at earlier использовавшемя a coupling disk gear gearing of a nave clear of a dirt and corrosion and to put a superthin layer of greasing on gear gearing. Directing plug do not grease.
If necessary check up centering of a conducted disk of coupling.
Check up the bearing of deenergizing of coupling on deterioration, if necessary replace.
At leaky landing of a plastic ring of the bearing of deenergizing paste a plastic ring of the bearing of deenergizing by means of glue AMV 195 KD1 01 to a ring подшиника.

Fig. 2.92. Rectangular ledges of a plastic ring of the bearing


Three rectangular ledges of a plastic ring will get to grooves of a ring of the bearing (fig. 2.92).
If grooves are deeper 0,5 mm – replace подшиник coupling deenergizings.
In engines of cars with a mechanical transmission the needle bearing in crankshaftу should be established. If necessary establish the bearing.

Cars with an automatic transmission
Clear Slots primary shaft КП and damperа a flywheel of a dirt and a rust and to put on them very thin layer of greasing. Surplus of greasing necessarily remove.

All cars
Check up presence in the block of cylinders of adjusting plugs for engine/transmission centering, if necessary insert plugs.

Fig. 2.93. Check of installation of a flange


Check up that on a flange the intermediate guard, and adjusting plugs насажены (fig. 2.93) is suspended.
Establish an intermediate guard on centering plugs between the engine and a check point.
Прифланцуйте the engine to a transmission also twirl one bolt by hand.
Lower the engine and thus establish a carving bolt of a pillow of the engine and the console of a pillow of the engine.

THE NOTE
The resulted moments of an inhaling are true for slightly greased, фосфатированных or оксидированных nuts and bolts.
Use of additional greasings, for example motor or трансмиссионных oils, except графитсодержащих is supposed.
Do not use fat-free details.
The admission of the moments of an inhaling makes ▒15 %.

Engine fastening to a mechanical transmission

Fig. 2.94. Engine fastening to a mechanical transmission


Look fig. 2.94.


Fastening the engine/transmission multitronic

Fig. 2.95. Fastening the engine/transmission multitronic


Look fig. 2.95.


The further installation is carried out in return sequence.
Establish and fix system of release ОГ without mechanical pressure.
Establish the conditioner compressor.
Establish the hydraulic booster pump.
Establish поликлиновый a belt.
Establish a framework of a radiator with hinged details.

Fig. 2.96. Fastening of the rubber buffer


Lower an emphasis of a support against проворачивания at the expense of a body weight on the rubber buffer and tighten nuts (fig. 2.96).
Establish a casing of a forward bumper.
Fix pipelines for трансмиссионного oils.
Observe rules of connection of the storage battery.

ATTENTION
For start of the engine do not use зарядное the device. There is a danger of damage of blocks of management in the car.

Check up oil level.
Fill in cooling liquid.

THE NOTE
To reuse the merged cooling liquid it is authorised only if the head of the block of cylinders or the block of cylinders have not been replaced.
The polluted cooling liquid is forbidden for using further.

The inhaling moments

Check up oil level in a tank of the hydraulic booster of the steering mechanism.
Check up level ATF.
Check up adjustment of headlights.


2.3. A Mehanichsky part (petrol engines 2,0л)

2.3.2. Removal and installation semi wedge a belt