Removal of the engine. Audi A4 (from 2001 to 2005 release)
Service of Audi A4 from 2001 to 2005 release.
1. Operation and maintenance of the car
2. Engine
2.1. General information
2.2. Predvaritlny checks
2.3. Mekhanichsky part (petrol engines 2,0l)
2.3.1. Removal of the engine
2.3.2. Removal and installation of a poliklinovy belt
2.3.3. Removal and installation of a belt pulley of the crankshaft
2.3.4. Removal and installation of a gear belt
2.3.5. Removal and installation of a sealing flange and flywheel / the conducted disk
2.3.6. Replacement of manzhetny consolidation of the crankshaft 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 the conducted disk
2.3.10. Removal and installation of a bent shaft
2.3.11. Removal and a press fitting of the needle bearing in the crankshaft
2.3.12. Removal and installation of an asterisk
2.3.13. Dismantling and assembly of pistons and rods
2.3.14. Head of the block of cylinders
2.3.15. Removal and installation of the valve of 1 system of change of phases of gas distribution
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. Check of a compression
2.3.20. Repair of the valvate mechanism
2.3.21. Removal and installation of the phase shifter
2.3.22. Removal and installation of cam-shafts
2.3.23. Replacement of oil scraper caps (at the established head of the block of cylinders)
2.3.24. Check of the directing plugs of valves
2.3.25. Replacement of manzhetny consolidation of a final cam-shaft
2.4. Lubrication system
2.5. Cooling system
2.6. System of injection
2.7. System of production of the fulfilled gases
2.8. Mechanical part (petrol engines 3,0; 3,2 l)
2.9. Mechanical part (petrol engines of 4,2 l)
2.10. Mechanical part (diesel engines of 2,0 l)
2.11. Tables
3. Transmission
4. Running gear
5. Steering mechanism
6. Brake system
7. Onboard electric equipment
8. Body
9. Schemes of electric equipment
 







2-3-1-snyatie-dvigatelya.html

2.3.1. Removal of the engine

NOTE
The engine is removed forward at the removed radiator frame.
At a stanovka install all fasteners of cables removed or which are cut off during dismantling on former places again.
For utilization or reuse cooling liquid should be merged in pure capacity.

Operating procedure
With the automatic transmission install the selector in situation "N" in cars.

Fig. 2.43. Mass cable of joint stock bank


Disconnect a mass cable from joint stock bank at the switched-off ignition (fig. 2.43).

ATTENTION
When opening the broad tank can come out hot steam or hot cooling liquid, wrap up a cover rags and carefully open a tank.

Open a cover of a broad tank of the cooling system.
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 the noise-insulating screen (fig. 2.44).

Fig. 2.45. Fastening of a forward noise isolation


Weaken quick disconnect couplings 1 and 2 and remove a forward noise isolation (fig. 2.45).
Where are available, weaken quick disconnect couplings 3 and remove the back noise-insulating screen.

Fig. 2.46. Holder of the noise-insulating crane


Turn off the holder of the noise-insulating screen (fig. 2.46).
Establish a casing of a front bumper.

Fig. 2.47. Air duct of the left intercooler


Remove air ducts of the right and left intercoolers (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 OZh (fig. 2.48).

Fig. 2.49. Collar of the lower hose of the cooling system


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

Fig. 2.50. An air duct hose to the intercooler and a pipeline arm with coolant


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

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

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

Fig. 2.51. Air ducts to the intercooler and to a turbocharger


Disconnect an air duct 2 to the intercooler from a frame of a radiator (fig. 2.51).

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


Press hoses to the cooling coil of the drive of the hydraulic booster by means of clips for hoses (fig. 2.52).
Put the device for oil pumping.
Disconnect hydraulic actuator hoses.

Cars with the automatic transmission
Put the device for pumping of oil under the transmission.

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


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

All cars

Fig. 2.54. Engine casing


Remove a casing of the engine (fig. 2.54).
Unscrew bolts.

Fig. 2.2. Air duct


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

Fig. 2.55. The top hose of the cooling system and electric shtekerny connection of the left and right sensors of safety cushions on a radiator frame


Turn off electric shtekerny connection 2 of the left and right sensors of safety cushions on a frame of a radiator (fig. 2.55).

Fig. 2.56. Electric shtekerny connection of a headlight


Disconnect electric shtekerny 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).
Put electric cables aside.

Fig. 2.58. Shtekerny sockets of sound signals


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

NOTE
Poses. 1 do not take into account.

Remove a bumper.

Fig. 2.59. Protection of a bumper



Fig. 2.60. Fastening of the left air duct


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

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


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

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

Unscrew fixing bolts of the condenser.

NOTE
To avoid damages of the condenser, and also pipelines and hoses of a contour of air conditioning system, it is necessary to watch that lines and hoses were laid without tightness, excesses and breaks.

Turn the condenser with the connected highways down.
Unscrew bolts at the left and on the right on a radiator frame.
Disconnect the hummock drive from the cowl lock.

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


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

Fig. 2.63. Fastening of the energopoglashchayushchy buffer


Unscrew bolts from the energopoglashchayushchy buffer (fig. 2.63) at the left and on the right.

NOTE
The assistant is necessary for removal of a frame of a radiator.

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

NOTE
Before removal of a poliklinovy belt mark the direction of the course with chalk or a felt-tip pen. Change of the direction of the course of earlier operated belt can lead to its damage


Fig. 2.64. Weakening of a poliklinovy belt


For weakening of a poliklinovy belt turn a tension damper in the direction of an arrow (fig. 2.64).
Record a tension element by means of a clamp.
Take off a poliklinovy belt.

Fig. 2.65. Electric socket of the sensor of level and temperature of oil


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

Fig. 2.66. Air conditioning system contour tube arm


Remove air conditioning system contour tube arm from the oil pallet (fig. 2.66).

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


Disconnect the shtekerny socket of 1 wire going to the electromagnetic coupling of the compressor of the conditioner (fig. 2.67).

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

Turn off the conditioner compressor from an arm.

NOTE
To avoid damages of the condenser, and also pipelines and hoses of a contour of air conditioning system, it is necessary you watch that lines and hoses were laid without tightness, excesses and breaks.

You 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. Weight wire, motor guard and hose of an absorber


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

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


Disconnect water hoses 1 and 2 and turn off fastening of a broad tank of the cooling system (fig. 2.69).
Disconnect the shtekerny socket going to the sensor of a signaling device of the OZh low level below on a broad tank of the cooling system.
Disconnect the electric socket from the sensor of pressure of pressurization 1.

Fig. 2.70. Electric socket of the sensor of pressure of pressurization and left hose of nadduvochny air


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

Fig. 2.71. Right hose of nadduvochny air


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

Fig. 2.72. Electric sockets lambda probes


Disconnect electric sockets 2 a lambda probe and the heater a lambda probe (the black socket) from an arm (fig. 2.72).

ATTENTION
Pressure of fuel has to be taken off before opening of any knot of high pressure.


Fig. 2.73. Connecting union of a fuel-supply line


Disconnect a fuel-supply line (the following fuel collect and immediately close all open openings) (fig. 2.73).
Disconnect behind on the engine the water hoses going to the heater heat exchanger.
Remove screen wiper levers.
Remove the deflector.

Fig. 2.74. Cover of the switching block


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

Fig. 2.75. Fixing of levers


Fix levers by a yoke by means of a treshchetka (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. 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 engine control unit on the engine.

Fig. 2.78. Bolt connections of the lamellar pump


Turn off bolt connections of 1 lamellar pump through openings in a pulley for a poliklinovy belt (fig. 2.78).

Fig. 2.79. The threaded connection on the back party of the lamellar pump


Turn off the threaded 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. Inlet hose of the air filter / turbocharger and electric sockets


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

Fig. 2.81. Electric socket of a flowmeter of air


Disconnect the electric socket 1 from a flowmeter of air (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. Heat-shielding screen of the right driveshaft


Turn off the heat-shielding screen of 1 right driveshaft (fig. 2.83).

NOTE
It is impossible to bend a demountable element of system of release more than on 10 °.


Fig. 2.84. Tightening collar


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

Fig. 2.85. 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. Electric socket of the switch of lamps of a backing


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

Fig. 2.87. Threaded connections of the engine / check point


Turn off threaded connections engine / KPP 1-3 and 7-11 (fig. 2.87) available from below.
Remove a starter and shift aside.
Disconnect shtekerny connection 3.
Turn off a nut of 1 collar.

Fig. 2.88. Removal of a starter


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

NOTE
Various fixing openings are intended for various engines.


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


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

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


Weaken on several turns the top nut on the left pillow of the engine (fig. 2.90).

Fig. 2.91. Posting of the power unit


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

NOTE
For alignment of a center of gravity position of the power unit of a level of hooks have to be inserted, as shown in the figure 2.91.

ATTENTION
Hooks and lock pins of device for posting have to be recorded by pins.

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

NOTE
Check whether all hoses and wires between the engine and a body are disconnected.

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

Installation of the engine

NOTE
At installation replace самоконтрящиеся nuts and bolts/screws.
Replace the bolts/screws tightened on a certain corner, and also sealing rings, manzhetny consolidations and sealing rings of round section.
Hoses and hose unions of system of pressurization of air have to be cleared before Ustanovka of oils and lubricant.

For fastening of all connections of hoses use collars of the corresponding series.
At the return Ustanovkaye establish all cable couplers where they were established initially.

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

NOTE
If the clutch plate does not change, it is not necessary to turn an adjusting ring.

New SAC press disks are already previously adjusted and do not demand adjustment.
And at earlier использовавшемя a clutch plate gear gearing of a nave clear gear gearing of a power shaft of dirt and corrosion and to apply a superthin layer of lubricant on gear gearing. Do not grease the directing plug.
If necessary check centering of the conducted clutch plate.
Check the bearing of switching off of coupling for wear, if necessary replace.
At leaky landing of a plastic ring of the bearing of switching off paste a plastic ring of the bearing of switching off by means of AMV 195 KD1 01 glue to a ring of a podshinik.

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 than 0,5 mm – replace a podshinik of switching off of coupling.
The needle bearing in the crankshaft has to be installed in engines of cars with the mechanical transmission. If necessary install the bearing.

Cars with the automatic transmission
Clear vents of main shaft KP and a damper of a flywheel of dirt and a rust and to apply on them very thin film of lubricant. Surely remove excess of lubricant.

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

Fig. 2.93. Check of installation of a flange


Check that on a flange the intermediate guard is suspended, and adjusting plugs are got (fig. 2.93).
Install an intermediate guard on centering plugs between the engine and the check point.
Priflantsuyte the engine to the transmission also twirl one bolt by hand.
Lower the engine and at the same time establish a carving bolt of a pillow of the engine and console of a pillow of the engine.

NOTE
The given moments of an inhaling are right for slightly greased, fosfatirovanny or oxidized nuts and bolts.
Use of additional lubricants, for example engine or gearbox oils, except grafitsoderzhashchy is allowed.
Do not use the fat-free details.
The admission of the moments of an inhaling makes ±15%.

Fastening of the engine to the mechanical transmission

Fig. 2.94. Fastening of the engine to the mechanical transmission


Watch fig. 2.94.


Fastening multitronic engine/transmission

Fig. 2.95. Fastening multitronic engine/transmission


Watch fig. 2.95.


Further installation is carried out in the return sequence.
Install and fix system of release of OG without mechanical tension.
Install the conditioner compressor.
Install the pump of the hydraulic booster.
Establish a poliklinovy belt.
Establish a radiator frame with hinged details.

Fig. 2.96. Fastening of the rubber buffer


Lower a support emphasis against a provorachivaniye at the expense of a body weight on the rubber buffer and tighten nuts (fig. 2.96).
Establish a casing of a front bumper.
Fix pipelines for gearbox oil.
Follow rules of connection of the rechargeable battery.

ATTENTION
For start of the engine do not use the charger. There is a danger of damage of control units to the car.

Check oil level.
Fill in cooling liquid.

NOTE
It is allowed to reuse the merged cooling liquid only if the head of the block of cylinders or the block of cylinders was not replaced.
The polluted cooling liquid is forbidden to be used further.

Inhaling moments

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


2.3. Mekhanichsky part (petrol engines 2,0l)

2.3.2. Removal and installation of a poliklinovy belt