Audi A3

Since 1997 of release

Repair and car operation



Audi A3
+ The maintenance instruction
+ Current leaving and service
- The engine
   Compression check in engine cylinders
   Check of the engine by means of the vacuum gauge
   Removal and installation of the bottom cover of an impellent compartment
   Removal and engine/rkpp installation
   + Four-cylinder petrol engines 1.6, 1.8 l
   + Diesel engines
   + Major repairs
   + Greasing system
+ Systems of cooling, heating
+ The power supply system and release of the fulfilled gases
+ Engine electric equipment
+ Manual box of a gear change
+ Automatic transmission and models with a full drive
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Electroschemes





Removal and engine/rkpp installation

THE GENERAL DATA

The engine of 1.8 l

The engine together with РКПП acts in film downwards. For removal of the block the engine/rkpp is required the crane. At all do not remove the block the engine/rkpp 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 some connections are necessary to turn on, four supports, and for a raising of the car the lift are required. Before installation of the engine wings in an impellent compartment should be protected 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 a various lining. As here it is not obviously possible to describe a lining of all possible variants, it is recommended before рассоединением to mark corresponding lines.

The necessary special tool and auxiliary material:

– The crane
– A clip for spring collars, for example, HAZET 798–5
– A load-lifting suspension bracket, for example, AUDI 2024 A
– Greasing MoS2, for example, AUDI G 000 100
– A Dinamometrichesky key on 5 … 50 Н•м
– A Dinamometrichesky key on 40 … 200 Н•м
– A cable connector

REMOVAL


ATTENTION

Cable connectors which act in film or cut at engine removal 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 the 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 the manufacturer or HUNDRED AUDI. Therefore familiarise with instructions in subsection Input of a code of a radio receiver.


2. Remove the storage battery, address to subsection Removal and installation of the storage battery.
3. Turn away bolts of fastening and take out the holder of the storage battery.
4. Remove the actuator, address to subsection Check, removal and installation of the traction relay of a starter.
5. Remove the case of the air filter, address to subsection Removal and installation of the case of the air filter.
6. Turn away 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 subsection Removal and installation of the bottom cover of an impellent compartment.
8. Remove the right power shaft, address to subsection Removal and installation of power shafts.
9. Disconnect the left power shaft from flange РКПП and adhere a wire to the stabilizer or the bottom.
10. Merge cooling liquid, address to subsection Replacement of a cooling liquid.
11. The engine of 150 h.p.: Remove connecting pipes between a turbokompressorom/radiator of forced air, turbokompressorom / the air filter and a radiator of forced air / the inlet pipeline. For this purpose remove collars from hoses.
12. Loosen the a tension клинового a belt also remove it, address to subsections Removal and installation ridge клинового a belt and Removal and installation клинового a belt.
13. Turn away bolts of fastening and remove the pump of the hydraulic booster from the holder, adhere its 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 subsection Removal and installation of the pump of the hydraulic booster of a wheel.


Cars with the conditioner:

ATTENTION

Contour of cooling of the conditioner do not open. Hit of a cooling liquid on a skin can cause обморожение.
Turn away 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. Turn away bolts of fastening of the compressor () and () 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 muffler and каталитический the converter, address to 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. Расстыкуйте штекерные connections–1 coils of ignition and–3 injectors. Disconnect a negative cable–2. On сопроводительно the engine of 150 h.p. is shown an illustration
19. Disconnect the vacuum pipeline–4 on a pressure regulator.
20. Disconnect at the engine and турбокомпрессора (engines of 150 and 180 h.p.) vacuum and soaking up hoses. If necessary put on hoses and connecting unions of marks to exclude an error at assemblage.
21. Расстыкуйте all штекерные connections from the engine and РКПП to a body.

ATTENTION

The fuel system is under pressure! Before opening шланговых joinings cover with their thick rag. After that cautiously 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 clearing buttons on муфте. Mark hoses a tape for simplification of the subsequent assemblage.
23. Close топливопроводы a film and rubber rings to exclude hit in dirt system.
24. Disconnect 2 hoses of a cooling liquid to the heat exchanger of a heater at a forward wall of an impellent compartment for what open collars.
25. Remove all hoses of a 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 subsection Removal and radiator and fan installation.
27. Cars with РКПП: 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 АТ: Turn away bolts of fastening and remove the holder of the pressure head pipeline of the hydraulic booster at a box support. Remove a cable of the selector at a check point, address to subsection Adjustment of a cable of the selector of switching of automatic transmission.
29. Turn away bolts of fastening of a pendular support below between a body and the block the engine/transmission.
30. Raise the car. It should be on distance not less and = 60 mm from the earth.
31. Put on the earth wooden брусок (marksman) in the sizes 40 х 30 sm and thickness of 15 sm for installation on it of the engine around the pallet картера.
32. Connect load-lifting device AUDI-2024A to a hook 3180 with eyes on the engine. Connect the vertical punched tyres to apertures 1 and 5 cross-section tyres. Insert from outside a flywheel of the engine a finger into the second aperture of the tyre, from outside a pulley in the third aperture. Apertures are considered from outside a hook.

ATTENTION

Apply on hooks and fixing pins lock pins. For the coordination with the unit centre of gravity the punched tyres 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 lifting of the unit.
34. Raise the block the engine/transmission the crane so that to unload engine support.
35. Turn on from above the right support of the engine/box.
36. Turn away bolts of fastening of a support of a box at the left
37. Check up, that all hoses and the pipelines going from the engine and a box to the chassis have been disconnected.
38. Pull the block the engine/box forward how much it probably and slowly lower on a wooden lining. Carry out operation cautiously not to damage mechanisms.

ATTENTION

Fix the block that it has not overturned.


39. If necessary, disconnect a box from the engine, address to subsection Removal and installation РКПП.
INSTALLATION
40. Check up presence 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 up coupling. Insert bolts of fastening the engine/box and tighten their established moment of an inhaling. Thus be guided by instructions in subsection Removal and installation РКПП.
42. Establish into place the block the engine/box and fix by hand new bolts.
43. Fix the pendular lever by hand new bolts.
44. Expose the block the engine/box strong rockings by his hands.
45. Fix support of the engine/box and the pendular lever according to the values of twisting moments resulted in Specifications. Thus all bolts at first tighten динамометрическим a 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 its moment 45 Н m.
47. Fix the pump of the hydraulic booster of a wheel, address to subsection Removal and installation of the pump of the hydraulic booster of a wheel.
48. Establish a starter, address to subsection Removal and starter installation.
49. Put on клиновой a belt and pull it, address to subsections Removal and installation ridge клинового a belt and Removal and installation клинового a 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 subsection Removal and installation of the case of the air filter.
52. The engine of 150 h.p.: Establish connecting pipes between a turbokompressorom/radiator of forced air, turbokompressorom / the air filter and a radiator of forced air / the inlet pipeline. Fix hoses collars.
53. Establish a reception pipe of the muffler/katalitichesky the converter with new consolidations, address to subsection Removal and installation of system of release.
54. Establish the left and right power shafts, address to 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 муфты 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 their clips.
58. Establish the fan of a radiator with the holder, address to subsection Removal and radiator and fan installation.
59. Cars with РКПП: Establish into place drives of switching and adjust them, address to subsection a gear change Drive.
60. Establish on РКПП the working hydrocylinder of a drive of coupling, address to subsection Removal, installation and coupling check.
61. Cars with АТ: Fix the holder of the pressure head pipeline of the hydraulic booster on a box support. Establish draught of the selector on a box and adjust it, to subsection Removal, installation and coupling check.
62. Connect electric wires according to the marks put at removal and fix them.
63. Fix electric wires on places of their former fastening. Fix their collars.
64. Establish into place and fix the holder of the storage battery.
65. Establish the battery, without attaching while a negative cable, address to subsection Removal and installation of the storage battery.
66. Check up, that electric wires, vacuum hoses, hoses of cooling and fuel hoses have been connected according to their marks.
67. Check up oil level in the engine and a transmission, if necessary fill in oil.
68. Check up antifreeze presence in a cooling liquid and if necessary add, address to subsections Replacement of a cooling liquid and Check of levels of liquids, the control of leaks.
69. Establish an engine cover on the inlet pipeline.
70. Establish the bottom cover of an impellent compartment, address to 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 automatics electric window lifterа, 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 up level of oil and cooling liquid. Check up tightness of all шланговых connections.
73. Check up adjustment of headlights, address to subsection Adjustment of light of headlights.

ATTENTION

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


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