Audi A3

Since 1997 of release

Repair and car operation



Audi A3
+ The maintenance instruction
+ Current leaving and service
+ The engine
+ Systems of cooling, heating
+ The power supply system and release of the fulfilled gases
+ Engine electric equipment
- Manual box of a gear change
   Removal and installation РКПП
   Gear change 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
+ Electroschemes





Removal and installation РКПП

THE GENERAL DATA

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

Engines of 1.8 l

REMOVAL

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 materials of subsection Check and replacement of brushes of the generator and a pressure regulator.


2. Remove a fan casing.
3. Расстыкуйте a socket of the gauge of a tachometre–1, and also the switch of back foggy lanterns–2.
4. Turn away bolts of fastening and disconnect демпфер and a cable of a drive of switching РКПП ().
5. Disconnect a cable of a drive of a choice of transfers from the directing lever () for what raise a pad in an arrow direction.
6. Disconnect a hose of the working cylinder at a cable support. Turn away bolts of fastening and disconnect a cable support on РКПП (are specified by arrows) and take aside.
7. Turn away 2 bolts of fastening and disconnect the working cylinder from РКПП and fix with the attached hydraulic pipeline on one side bodies.
ATTENTION

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


8. Disconnect a wire of weight from the top bolt–1 connections the RKPP/ENGINE. Turn out a bolt–1.
9. Disconnect the holder of a cable–3 above at a starter (the marksman on an illustration) and take aside.
10. Turn away a bolt–2 above at a starter.
11. Turn out all bolts of fastening accessible from above between the engine and РКПП.
12. Will hang out the engine. For this purpose establish the adaptation, for example, AUDI 10–222A in a combination to support 10–222А/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 бруски. Do not put a pipe on wings. Hook for eyes of the engine on cables and connect to the screw. Pull a cable.
ATTENTION

At lifting and car installation on supports there is a danger! Therefore preliminary familiarise with subsection of Poddomkrachivanie of the car.


15. Lift and establish the car on supports. Remove the bottom cover of an impellent compartment, thus address to subsection Removal and installation of the bottom cover of an impellent compartment.
16. Remove a starter.
17. Turn away bolts of fastening and remove the holder of a wire of a drive of the hydraulic booster at картера РКПП.
18. Remove, if is available, a protective cover of the right flange of a power shaft ()
19. Turn away a fastening bolt (the top arrow) small cover behind the right power shaft and uncover.
20. Turn away bolts of fastening of power shafts and disconnect, thus address to 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 catalytic the converter and the central muffler, thus address to subsection Replacement of the central/additional muffler.
23. Turn away bolts of fastening and disconnect a pendular support between a body and sideways the engine/rkpp (the marksman on an illustration).
24. Turn away bolts of fastening and disconnect a bar of support РКПП at the left (an arrow And on an illustration), then disconnect support РКПП (an arrow In on an illustration).
25. Turn away bolts of fastening of support РКПП () on a box and disconnect. To take out fastening bolts (are specified by arrows), lower the block the engine-rkpp by means of spindles so that bolts were accessible from outside the left wheel arch.

ATTENTION

At unit lowering watch to damaging pipelines of the hydraulic booster of a wheel.


26. Fix the special tool () a bolt () at fastening of a pendular support from below. Insert the adaptation for отжима () and fix bolts (are specified by arrows). Wring out the block the engine-rkpp forward.

ATTENTION

If the special tool available is not present, the block the engine-rkpp can be shifted forward an onboard jack. Thus watch to damaging pipelines of the hydraulic booster of a wheel.


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

ATTENTION

Lay between РКПП and a jack a wooden lining.


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

At съеме РКПП watch to damaging the hydraulic booster pipeline.


INSTALLATION
ATTENTION

If РКПП it is replaced, rearrange the speedometer gauge, the lever of inclusion of transfers and the lever of switching with old РКПП on the new.


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

The coupling disk should move easily on a shaft.


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

Bolts at an inhaling receive residual deformation. Therefore after everyone отворачивания new bolts are applied.


45. Establish power shafts, thus address to subsection Removal and installation of power shafts.
46. Establish the big and small covers of power shafts.
47. Establish the left bolts of fastening of the holder of the engine and fix the moment 50 Н 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 support of a cable the moment 25 Н m to РКПП.
50. Fix a cable of switching by the moment 25 Н m to the gear change lever.
51. Connect a cable of a drive of a choice to the switching lever.
52. Fix a counterbalance on the gear change lever. Tighten fastening bolts at first динамометрическим a key the moment 20 Н m and then tighten a rigid key on a corner 90 (1/4 turns).
53. Adjust a gear change drive, address to subsection Adjustment of a drive of switching.
54. Fix a socket at РКПП, thus address to subsection "Removal".
55. Join a socket at a starter.
56. Grease the end of a rod of the working cylinder of a hydrodrive with greasing MoS2. Insert into place the working cylinder and fix its moment 20 Н m
57. Some times press a pedal of coupling and check up work.
ATTENTION

If the hydrodrive opened, remove from system air.


58. Establish a reception pipe/katalitichesky the converter with new sealing linings, thus address to subsection Removal and installation of system of release.
59. Fix the holder of the pipeline of the hydraulic booster of a wheel on картере РКПП, thus address to subsection Removal and installation of the pump of the hydraulic booster of a wheel.
60. Check up oil level in РКПП, thus address to subsection level Check трансмиссионного oils РКПП.
61. Establish the bottom cover of an impellent compartment, thus address to subsection Removal and installation of the bottom cover of an impellent compartment.
62. Establish the case of the air filter, thus address to subsection Removal and installation of the case of the air filter.
63. Attach a negative cable (–) to a battery accumulator room.
ATTENTION

Make active automatics of safety electric Glass lifts, 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 remark, concerning all РКПП, of 1.8 l are resulted in subsection for engines. In the present subsection the differences concerning only to the engine of 1.6 l are described only. These of differences concern, first of all, a drive of switching which for the engine of 1.6 l occurs through draughts, 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 draught–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 draught with демпфером–5. Reject draught with демпфером upwards and remove from a support of the bearing–6.
67. Disconnect by means of a screw-driver long connecting draughts from the lever of a choice of transfers (are specified by arrows). Turn away a bolt and disconnect the forward lever of switching–1 at РКПП.
68. Turn out bolts–2 and remove the console of switching–3 with connecting draughts and the switching lever
69. Disconnect a hose of the working cylinder at a support. Turn away 2 bolts of fastening and disconnect the working cylinder (are specified by arrows) at РКПП 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 installation РКПП it is necessary to make adjustment of a drive of switching, thus address to subsection Dismantling of a shaft of a drive.


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