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





Removal, installation and coupling check

THE GENERAL DATA

The bearing of deenergizing of coupling, картер РКПП. Engines of 1.8 l

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

ATTENTION

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


The bearing of deenergizing of coupling, картер РКПП. Engines of 1.6 l

1 – a cover
Removal: Punch sharp оправкой and remove, having hooked.
Installation: Sealing surfaces should not contain some greasing. A new cover press on a circle corresponding оправкой.
2 – the bearing of deenergizing of coupling
Can be replaced without removal РКПП.
3 – the lever of deenergizing of coupling
Removal: Remove lock скобу (5). Sideways take out a shaft (9).
The lever can be inserted only in one position.
4 – the plug
5 – lock скоба
6 – the needle bearing
7 – the plug
8 – a sealing ring
9 – a shaft of deenergizing of coupling
10 – cover РКПП
11 – a stopper of a mouth for oil pouring, 25 Н•м

Engines, except 1.6 l

(The description of works for engines of 1.6 l is resulted more low)

REMOVAL

PERFORMANCE ORDER
1. Remove РКПП, thus address to subsection Removal and installation РКПП.
2. To exclude flywheel rotation at отворачивании fastening bolts, it is necessary to keep it tool AUDI-3067 or a screw-driver and a core.

ATTENTION

Tool AUDI-3067 on an illustration is shown in installation position. At removal it is necessary for turning. For coupling installation it is required aligning оправка AUDI–3190А or a usual aligning core, for example, HAZET 2174.


3. Turn away bolts of fastening of a press disk cross-wise everyone on 1 – 1, 5 turns 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 assemblage in coupling work there can be jerks and difficulties in deenergizing.


6. Wipe the bearing of deenergizing 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 up preliminary.
8. Check up press a disk on presence of places of an overheat and задиров.
9. Check up press springs on presence of damages (are specified by arrows). Deterioration to half of thickness of a spring is supposed.
10. Check up connections of springs between a press disk and a cover on presence of cracks. Zaklepochnye connections check up on durability. In the presence of weak connections or damages coupling replace.
11. Check up an adjoining surface of a press disk on presence of cracks, overheat and deterioration places. In the presence of deformation of a press disk to 0.2 mm in it still it is possible to use. Check is spent by a ruler and probeом.
12. Check up a flywheel on presence of cracks of an overheat and задиров.
13. The greasy or having mechanical damages a coupling disk replace with the new.
14. Check up a thickness of frictional overlays of a disk of coupling and presence of cracks in overlays.
15. In conditions HUNDRED disk of coupling can be checked up on palpation. Face palpation of a disk should not exceed 0.8 mm (2.5 mm measured on 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 lacks of its work. If necessary the disk can be cautious отрихтован.


16. Check up by hand the bearing of deenergizing of coupling in the established position. For this purpose slightly compress the bearing and turn. The bearing should rotate easily. At work damage of the bearing of deenergizing of coupling is defined on 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 up press a disk and a conducted disk under the catalogue of spare parts on their conformity to exclude erroneous installation.


17. Before installation of a new press disk the protective anticorrosive layer should be removed only on the working party. In other places greasing does not leave at all, otherwise it can lead to essential decrease in service life of coupling.
18. Check up durability of fastening of aligning pins on a flywheel.
19. Clear шлицы a conducted disk of a rust. Grease with a thin layer of greasing MoS2 шлицы primary shaft РКПП. HUNDRED applies for this purpose AUDI G 000 100. After that move a conducted disk on a shaft, having checked up ease of a course. Surplus of greasing necessarily 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 overlay adjoined to a flywheel. The nave should not adjoin at a flywheel, the short end of a nave shows towards a press disk.


21. Centre a conducted disk on a press disk by means of a core, for example, HAZET 2174 or AUDI - 3176 (are specified by arrows). If the conducted disk is located not on the centre, the primary shaft cannot occupy the working position. As an aligning core old primary shaft РКПП can be applied.
22. Establish press a disk on corresponding aligning pins.
ATTENTION

Press the disk should adjoin completely to a flywheel and should not warp. Aligning pins and apertures otherwise can be damaged. Only after that insert fastening bolts. At all do not pull together press a disk with bolts, aligning apertures 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 has been fixed. The inhaling moment: 20 Н m.
ATTENTION

At execution with screws with internal шестигранником the last are tightened by the moment 13 Н m.


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

Mark position of a flywheel concerning a press disk that they could be established in former position. If the flywheel is established incorrectly, marks ВМТ on a flywheel lose the position.


28. Turn away bolts of fastening of a flywheel one after another 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 assemblage in coupling work there can be jerks and difficulties in deenergizing.


31. Hook a screw-driver and take out from apertures (are specified by arrows) a lock ring () a disk of deenergizing of coupling ().
32. Remove a disk of deenergizing of coupling ().
33. Disconnect press a disk from a flywheel for what fix on a press disk tool AUDI 558 bolt (). If the specified tool available is not present, press the disk can be kept a screw-driver and оправкой.
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 up preliminary.
36. Check up заклепочные connections on a press disk. A disk with damaged or weakened заклепочными connections replace with the new.
37. Check up a frictional surface of a press disk on presence of cracks, overheat and deterioration places. In the presence of deformation of a press disk to 0.2 mm in it still it is possible to use. Check is spent by a ruler and probeом.
38. Wipe from oil frictional surfaces of a press disk and a flywheel.
39. The greasy or worn out conducted disk replace with the new.
ATTENTION

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


INSTALLATION
ATTENTION

If new details of coupling are established, it is necessary to check up press a disk and a conducted disk under the catalogue of spare parts on their conformity to exclude erroneous installation.


40. Before installation of a new press disk the protective anticorrosive layer should be removed only on the adjoining and frictional party. In other places greasing does not leave 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 position of installation of an intermediate plate. (The arrow on an accompanying illustration) shows an eminence aside from a press disk. Screw new bolts of fastening and block press a disk as at removal by tool AUDI-556 or a screw-driver and оправкой.


42. Fix press a disk динамометрическим a key the moment 60 Н 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 everyone отворачивания it is necessary to replace them with the new.


43. Insert a disk of deenergizing of coupling and fix a lock ring on a press disk. Insert both ends of a wire into apertures of a press disk.
44. Clear шлицы a conducted disk of a rust. Grease with a thin layer of greasing MoS2 шлицы primary shaft РКПП. HUNDRED applies for this purpose AUDIG 000 100. After that move a conducted disk on a shaft, having checked up ease of a course. Surplus of greasing necessarily remove.
45. Check up 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 up 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, marks ВМТ on it occupy incorrect position.
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 apertures otherwise can be damaged. At all do not draw a basket of coupling by bolts since pins and aligning apertures otherwise can be damaged.


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