Audi A4, S4

Since 2000 of release

Repair and car operation



Audi A4, S4
- Introduction
   About this Management
   Cars Audi A4/S4 - the summary
   Identification numbers of the car
   Acquisition of spare parts
   Technology of service, the tool and the workplace equipment
   Поддомкрачивание and towage
   Start of the engine from the auxiliary storage battery
   Automobile химикалии, oils and greasings
   Diagnostics of malfunctions
+ Controls and receptions of safe operation
+ Current leaving and service
+ The engine
+ Systems of cooling, heating and the air conditioner
+ Power supply systems, release and decrease in toxicity of the fulfilled gases
+ Systems of an electric equipment of the engine
+ Manual box of a gear change
+ Automatic transmission
+ Coupling, power shafts and differential
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment



Technology of service, the tool and the workplace equipment

Technology of service

There are some techniques of performance of procedures of maintenance service and car repairs on which the reader will find references in the text of the present Management. Following to offered instructions will make work of the mechanic-fan of more effective, will allow to organise in the best way and qualitatively to execute various technical procedures and is pledge of half-number performance of all necessary works.

Fixture — the general information

As fixture are called nuts, bolts, hairpins and the screws serving for connection among themselves of two or more details. At work with fixture elements it is necessary to remember some things constantly. Practically in any carving fixture this or that kind контрящих and stopping adaptations is applied. It can be lock washers, counternuts, lock tags or special fixing hermetic for carving connections. All used fixture should be absolutely pure and direct, with not broken carving and not rounded corners шестигранных heads on a turn-key basis. It is necessary to take for a rule without fail to make replacement of the damaged elements of fixture. Special самоконтрящиеся nuts with nylon or fiber inserts are not subject to a reuse, as at отдавании lose the контрящие properties and at assemblage always should be replaced.

"The become attached" fixture for the purpose of simplification of unscrewing and in order to avoid damages before отдаванием should be processed special getting structure. Many mechanics prefer to use for this purpose turpentine which it is convenient to put from the special small canister with a long nouse. After fixture wetting by getting structure, it is necessary to give to means within several minutes properly to impregnate the oxidised contact layer. Strongly rusted fixture can be cut down a chisel, is cut ножовкой or removed by means of special гайколома.

At cutting of a head of a bolt or обламывании hairpins on assemblage the rest of a carving part can be drilled or taken by means of a special ex-tractor. The majority of repair trucks can undertake performance of this, no less than others (for example, restoration of the broken carving in carving apertures), repair procedures.

Flat and lock washers at assemblage should be established always into place in the original positions. The damaged washers are subject to replacement without fail. Between a lock washer and a soft metal surface (for example, aluminium), thin sheet metal or plastic of a fixed detail always it is necessary to establish flat washers.

The sizes and classes of durability of fixture

For many reasons manufacturers of cars all apply metric fixture more widely and more widely. However, it is important to know a difference between this (more universal) fixture and fixture of standard SAE used sometimes (or American). Despite external similarity, elements of these two types of fixture are not interchangeable.

All bolts as standard SAE, and metric, are classified on diameter, a step of a carving and length. For example, the bolt of standard SAE 1/2 - 13 x 1 has half of inch in diameter, 13 coils of a carving on one inch and length of 1 inch.

The sizes/marks of a class of durability standard (SAE and USS) bolts

G — marks of a class of durability
L — length (in inches)
T — a carving step (quantity of coils on inch)
D — nominal diameter (in inches)

Metric bolt М12 — 1.75 x 25 has diameter of 12 mm, a carving step (distance between the next coils) 1.75 mm and length of 25 mm.

The sizes/marks of a class of durability of metric bolts

P — a durability class
L — length (in mm)
T — a carving step (distance between the next coils in mm)
D — nominal diameter (in mm)

Both bolts are outwardly almost identical, however are not interchangeable.

In addition to the listed signs, both metric bolts, and bolts of standard SAE can be identified visually by head survey. To begin with, the distance between лысками шлицов heads of a metric bolt is measured in millimetres, whereas at American - in inches (the same is fair and for nuts). As consequence, the wrench of standard SAE is not necessary for use with metric fixture, and on the contrary. Besides, on heads большей parts of bolts of standard SAE usually are available the radial notches defining the maximum admissible effort of a tightening (durability degree) bolt. The more quantity of notches, the above admissible effort (on cars bolts of a class of durability from 0 to 5 are usually applied). The class of durability of metric bolts is defined by a digital code. Code figures are usually cast also on a bolt head (on cars bolts of classes of durability 8.8, 9.8, and 10.9 are usually applied).

Marks of a class of durability of bolts

Above — standard/SAE/USS
Below — metric

Also, on labels of a class of durability, it is possible to distinguish nuts of class SAE from the metric. Dot labels are applied to identification of a class of durability of standard nuts, проштамповываемые on one of face surfaces while marks of metric nuts are made by means of, besides, digital code. The more quantity of points/values of a digital code, the above admissible effort of a tightening of a nut.

Marks of a class of durability standard шестигранных nuts

Shestigrannaja nut
Class of durability 5
Class identification — Three points

Shestigrannaja nut
Class of durability 8
Class identification — Six points

Marks of a class of durability metric шестигранных nuts

Shestigrannaja nut
Class of durability 9
Class identification — Arabian 9

Shestigrannaja nut
Class of durability 10
Class identification — Arabian 10

End faces of metric hairpins also are marked according to a class of their durability. The digital code whereas on smaller have marks in the form of geometrical figures is put on large hairpins.

Marks of a class of durability of metric hairpins

1 — the Class of durability 10.9
2 — the Class of durability 9.8
3 — the Class of durability 8.8

It is necessary to notice that the considerable part of fixture, in particular a class of durability from 0 to 2, is not marked at all. In this case unique way of difference of the American fixture from metric is measurement of a step of a carving, or сравнивание coils with coils of unequivocally identified element.

It is necessary to remember that under classification SAE only small fixture gets. Larger elements with not metric carving is fixture of the American standard (USS).

As the fixture of the same geometrical size (both standard, and metric) can have various classes of durability, at replacement of bolts, nuts and hairpins it is necessary to give particular attention to conformity of a class of durability established new elements removed on a durability class.

Technique and order of a tightening of carving connections

The tightening большей should be made parts of carving connections with the efforts defined by requirements of Specifications, resulted in the beginning of each Chapter of the present Management (it is necessary to understand a twisting moment put to it as effort of a tightening of fixture). The tightening with excessive effort can lead to infringement of integrity of fixture whereas недотягивание it conducts to unreliability of a joint of interfaced components. Bolts, screws and hairpins, depending on a material of which they are made, and diameter of a carving part, usually have strictly certain admissible efforts of a tightening, many of which as already it was mentioned above, are resulted in Specifications in the beginning of each Chapter. Strictly adhere to the resulted recommendations about efforts of a tightening of fixture applied on the car. For a tightening of the fixture which has been not mentioned in Specifications, it is necessary to use the map of admissible twisting moments resulted more low. The values resulted in the table are focused on fixture of classes of durability 2 and 3 (more high-class fixture supposes a tightening with the big effort), besides, it is meant that the tightening dry (with not greased carving) the fixture screwed in steel or cast (not aluminium) a detail is made.

Metric carvings

М6

9—12 Н•м

М8

19—28 Н•м

М10

38—54 Н•м

М12

68—96 Н•м

М14

109—154 Н•м

Trumpet carvings

1/8

7—10 Н•м

1/4

17—24 Н•м

3/8

30—44 Н•м

1/2

34—47 Н•м

Carvings of the American
The standard

1/4 — 20

9—12 Н•м

5/16 — 18

17—24 Н•м

5/16 — 24

19—27 Н•м

3/8 — 16

30—43 Н•м

3/8 — 24

37—51 Н•м

7/16 — 24

55—74 Н•м

7/16 — 20

55—81 Н•м

1/2 — 13

75—108 Н•м

Located on perimetre of any component the fixture (such as bolts of a head of cylinders, the pallet картера and various covers) in order to avoid detail deformation should be given and be tightened in strictly certain order. The order of a tightening and отдавания such fixture is resulted in the text of corresponding Heads of the Management, and also on сопр. Illustrations. If the special order is not stipulated, in order to avoid component deformation, it is necessary to adhere resulted below instructions.

At the first stage all bolts/nuts should be tightened by hand. Further, each of fixture elements by turns reaches on one complete revolution, and transition from one bolt/nut to another should be carried out in a diagonal order (cross-wise). Further, having returned to the first element, it is necessary to repeat procedure in the same order, tightening fixture for a half-turn. Continue procedure performance, holding out each element already on a turn quarter for one approach until all of them will not appear tightened with demanded effort. At отдавании fixture it is necessary to operate in a similar manner, but upside-down.

Dismantling of components

Dismantling of all components should be carried out in such manner that at installation each detail could be established on the former place and correct image. Try to remember characteristic external features of knot in gathering, in case of need, make landing marks of the details which installation can be into place executed in the ambiguous image (for example, the persistent washer equipped with a flute on a shaft, etc.). Placing of the removed details on a pure working surface in that order in what their removal was made will be good idea. Useful there will be also a drawing up of the elementary schematic sketches or step-by-step photographing of an assorted component.

At отдавании fixture try to make marks of its initial position on assemblage. Often, installation of fixture and washers on a former place right after removal of a corresponding detail allows to avoid mess at assemblage. In the absence of such possibility, all fixture should be put in specially prepared for this purpose broken into sections and in appropriate way the marked box, or it is simple on the separate marked boxes. Such approach appears especially useful at work with the components consisting of set of fine details, such as the carburettor, the generator, клапанный the mechanism, the panel of devices or elements of a decorative upholstery of salon.

At a detachment of electric contacts and sockets it is necessary to pay attention to marks of wires or plaits by means of an adhesive tape with the digital on it digital or alphabetic code.

Prokladochnye surfaces

On all cars sealing linings are applied to hermetic sealing of a place of a joint of interfaced surfaces of two or more details and serve for prevention of leaks of oils and other working liquids and maintenance in assemblage of the raised pressure/depression.

Often such linings before installation become covered liquid or pastelike sealing компаундом (hermetic). Sometimes, eventually, or under the influence of the raised temperatures or pressure occurs so strong «прикипание» interfaced surfaces to each other that the partition of details becomes an exigeant problem. With many cases to successful separation of the "become attached" components helps обстукивание them outside on perimetre of a joint a hammer with soft the brisk. It is possible to take advantage for this purpose as well of a usual hammer, putting blows through the wooden or plastic prorate. It is not necessary to make обстукивание cast cases and components sensitive to concussion. At occurrence of such difficulties always first of all check, whether weigh fixture it is removed.

Avoid подрычаживания details by means of a screw-driver or the mount, entered into joint area as thus interfaced surfaces can be easily damaged that further will lead to development of leaks. If to avoid подрычаживания "the become attached" elements of assemblage it is not possible, use for this purpose the handle from old сметки, but remember that all formed chips should be carefully removed both from interfaced surfaces, and from internal cavities of components of the dismembered knot.

After division of details their interfaced surfaces should be smoothed carefully out with application of a scraper for removal of traces of a material of an old lining. The hardened fragments can be preliminary softened by means of the converter of a rust or a special chemical compound. As a scraper the piece of a copper tube with the flattened out and pointed end in this case can be used. The rests of some linings easily can be removed by means of a copper brush, however, without dependence from the applied method, interfaced surfaces as a result of processing should become absolutely pure and dry. If for any reason the interfaced surface has appeared is damaged, before knot assemblage fill defects прокладочным with hermetic. In most cases it is necessary to use not stiffening (or not up to the end stiffening) hermetic.

Councils about removal of hoses

If your car is equipped by air central air, at all do not disconnect from system components any hoses until the path will not be discharged on a car repair shop by the expert in air central airs.

Measures of precautions which should be observed at removal of hoses, are very close to the measures shown at dismantle of linings. Avoid damage of surfaces of unions and branch pipes on which the ends of hoses as it can be at the bottom of development of leaks stretch.

In a special measure last requirement concerns procedure of removal of hoses of a radiator. Owing to occurring in a path of system of cooling of various chemical reactions frequently occurs «прикипание» rubbers of hoses to surfaces of unions and branch pipes. For hose removal first of all ослабьте a collar of its its fastening. Then nippers seize a hose near to a collar and start to rotate it on the union / a connecting branch pipe to the right-to the left. Continue to operate in the stated manner to a hose outright release, then remove a hose from the union.

The small amount of the silicone or other greasing entered into a backlash between the union and a hose, will allow to save forces. Before hose installation grease its internal surface adjoining to an end face, and also an external surface of the union with a solution of soap water or a small amount of silicone greasing.

As extreme means, or in case of unequivocal necessity of replacement of a hose on the new end of a hose put on the union can be knifed and then is separated from an union surface. Thus try not to damage an edge union metal / a connecting branch pipe.

In case of damage шлангового a collar, replace it with the new. Collars of braided type usually weaken in due course, therefore, without dependence from a condition, it is better to replace them more practical screw or worm.

The tool

Selection of the qualitative tool is one of basic requirements for everyone who plans independent performance of procedures of maintenance service or car repairs. At first sight, the expenses connected with acquisition of the demanded complete set of tools, can seem incommensurably big, however at сравнивании them with the expenses interfaced to performance of procedures of routine maintenance and the elementary car repairs on a car repair shop, will appear quite reasonable.

For the purpose of approach ordering three lists of tools conditionally entitled as are more low resulted in a choice necessary at repair and service of the car of the tool:« Tooling for routine maintenance and the minimum repair "," the Tooling for the general and major repairs "and" the Special tool ». The owners of cars who do not have practical experience of carrying out of mechanical works, should begin with performance of the procedures limited to application of tools from the first list, raising thus qualification and gradually expanding a range of the activity. In process of acquisition of skills, it is possible to pass to performance more challenges, gradually filling up assortment of tools available on hands. After a while the gained experience will allow to pass to performance of more difficult works demanding application of the tool from the second list (for the general and car major repairs). When qualification of the executor will reach enough high level and will allow to save considerable means for independent performance of difficult repair procedures, it is possible to think of acquisition of the special tool.

Tooling on routine maintenance and the minimum car repairs

The list resulted more low includes a minimum of units of the tools necessary for performance of procedures of routine maintenance and insignificant car repairs. Composers of the present Management recommend to begin with acquisition of the complete set of the combined wrenches (with usual рожковой a head on one end and with накидной on other). Despite the raised cost of the given complete set in comparison with cost of a set usual рожковых keys, expenses will be justified, since such keys possess advantages of both types.

  • The complete set of the combined keys from 8 to 19 mm
  • Adjustable spanner (to 35 mm)
  • Candle key with a rubber insert (petrol models)
  • The tool for adjustment of a candle backlash (petrol models)
  • Set measuring probeов
  • Nippelnyj key for prorolling of brakes
  • Screw-drivers:
    • With a flat sting (100 mm in length and 6 mm in diameter)
    • With крестовым a sting (100 mm in length and 6 mm in diameter)
  • The combined flat-nose pliers
  • Ножовка on metal with a set of cloths
  • The pump for a rating of tyres
  • Manometre for pressure measurement in tyres
  • Lubricant pistol (syringe)
  • The canister under oil
  • Fine-grained emery paper
  • Wire brush
  • The tool for зачистки plugs and contacts of wires of the battery
  • Key for removal of the oil filter
  • Funnel (the average size)
  • Props for car fixing in the lifted condition (2)
  • Drain capacity
  • If routine maintenance procedures include carrying out of base adjustments, acquisition of a qualitative stroboscope and the combined tachometre/tool for measurement of duration of the closed condition of contacts of the breaker is required also. In spite of the fact that these tools are a part of the list of special tools, the mention of them here is resulted in a kind of an absolute necessity of their application for carrying out of qualitative adjustment of ignition of the engine, being part of procedures of routine maintenance of the car.

    Tooling for the general and car major repairs

    The given tool is absolutely necessary at carrying out of any operations on repair of the engine of the car and it is offered in addition to the first list. The complete set of replaceable face heads is included in the present list. At considerable cost, the set of replaceable heads brings invaluable advantage, thanks to the universality and convenience in circulation, in particular in a combination to drives of various type entering into the complete set. It is recommended to prefer drives inch section 1/2 (instead of 3/8 inches) since they though are more expensive, can be used practically with any type динамометрических keys (in an ideal, the good mechanic should have at the order both types of drives). Cheaper alternative to the complete set of replaceable face heads is the set of tubular keys.

  • The complete set of replaceable face heads (including type heads «TORХ») (or tubular keys), the sizes corresponding to the sizes of wrenches from the previous list
  • Ratchet reversive drive (for use with replaceable face heads)
  • Collar in length of 250 mm
  • Kardannyj drive (for use with replaceable face heads)
  • Dinamometrichesky key (with a drive of the same size, as for replaceable face heads)
  • Самоконтрящиеся nippers
  • Hammer with round brisk (nearby 230 )
  • Hammer with soft brisk (plastic or rubber)
  • Screw-drivers:
    • With a flat sting (length 150 mm and about 6.5 mm in diameter)
    • With a flat sting (strong № 2, 8 mm)
    • With крестовым a sting (№ 3 x 8 inches (203 mm))
    • With крестовым a sting (strong № 2)
  • Clamping pincers
  • Flat-nose pliers:
    • For electricians (with the isolated handles)
    • Узконосые (nippers)
    • For lock rings (internal and external)
  • Chisel on 25 mm
  • Scraper (made of the copper tube flattened out and pointed from one end)
  • Скрайбер (чертилка)
  • Кернер
  • Small beards with a thin sting (1.6, 3.2, 4.8 mm)
  • The complete set шланговых clips
  • Set for prorolling of brakes
  • The complete set of drills
  • Steel ruler / a planeness measuring instrument
  • The complete set прутковых keys-shestigrannikov (Allen) (for heads with internal шестигранником)
  • Set of files
  • Wire brush (big)
  • The second complete set of props
  • Jack (hydraulic or ножничного type)
  • Resock with the closed lamp shade
  • One more constantly required tool is the electrodrill with a cartridge on to 9.5 mm with the complete set of high quality of drills.

    The special tool

    The tools being adequately expensive, not required regularly, or demanding at use performance of instructions of manufacturers get to the given category. If the field of activity of the mechanic-fan does not include frequent performance of difficult mechanical operations, acquisition of such tool becomes a bad investment of means - it will be more reasonable to get it by sharing the cost with friends, or as required to hire in car-care centre workshops.

    Those tools which can be found in retail trade or which are issued for distribution on the services-centres of representation branches of the companies-manufacturers of cars are brought in the list only. Sometimes in the text of the Management the reader will face references to such special tools. Usually authors try to offer in parallel the alternative method, allowing to avoid obligatory application of the remote tool. In a case if to avoid application of the special tool it is impossible, and its acquisition in using is problematic, performance of corresponding works will entrust more correctly to experts of car-care centre.

  • The tool for compression клапанных springs
  • The tool for grinding in of valves
  • The adaptation for procleaning of flutes of piston rings
  • The tool for обжимания piston rings
  • The tool for installation of piston rings
  • Measuring instrument of degree of compression of gases in cylinders (компрессометр)
  • Vertical drill for processing of edges of cylinders
  • Хон for processing of mirrors of cylinders
  • Measuring instrument of diameter of cylinders
  • Micrometer (micrometers) and-or циферблатный a calliper
  • The tool for centering of a disk of coupling
  • Ex-tractor of spherical hinges
  • Stripper of universal type
  • Shock screw-driver
  • Set циферблатного a measuring instrument
  • Stroboscope (with the inductive gauge)
  • The manual combined pump (vacuum/delivery)
  • Set of taps and лерок
  • Tachometre/tool for measurement of duration of the closed condition of contacts of the breaker
  • Universal tester for electric measurements
  • Elevating rigging
  • The tool for removal/installation of brake springs
  • Тележечный (подкатной) a jack
  • Micrometer with the complete set from nozzles

    Tsiferblatnyj measuring instrument with the complete set of clamps and nozzles

    Tsiferblatnyj/нониусный a calliper

    The vacuum pump with a manual drive

    Stroboscope

    Measuring instrument of a compression with a nozzle for installation in candle apertures

    Stripper for removal dempfera/a steering wheel

    General purpose stripper

    The tool for removal of hydraulic pushers

    The tool for compression клапанных springs

    The tool for compression клапанных springs

    Vertical drill for removal of step deterioration in the cylinder

    The adaptation for procleaning of flutes of piston rings

    The tool for removal / of installation of piston rings

    The tool for обжимания piston rings

    Хон for processing of mirrors of cylinders

    The tool for removal of cups of directing springs of brake boots

    Хон for processing of brake cylinders

    The tool for centering of disks of coupling

    Set of taps and лерок

    Tool acquisition

    To the beginner-mechanic can be offered some practical advice in respect of acquisition of the tool necessary for performance of procedures of service and car repairs. By preparation for carrying out of procedures of routine maintenance or the minimum car repairs it is reasonable to get the tool separately. On the other hand, in case of planning of more large-scale works, it is easier and more reliable to buy the complete set of the modern tool in shop of a retail network. Complete set acquisition usually manages slightly more cheaply individual purchases and is often accompanied by the appendix in the complete set of a tool box. Further, for assortment expansion, separate tools, additional complete sets and a tool box большего can be bought in addition the size. Gradual expansion of the complete set of tools will allow to stretch expenses and to be defined in a choice of really necessary tools.

    Specialised tool shops are a unique source of acquisition of some special tools. Without dependence from a source choice, avoid cheap purchases, in particular at a choice of screw-drivers and replaceable face heads as term of their service for certain will appear short. The expenses connected with replacement and restoration of the cheap tool, as a result will appear incomparably more considerable, than expenses for unitary acquisition of the qualitative goods.

    Care of the tool and its storage

    The good tool is a valuable investment of means, therefore it is reasonable to take care of keeping it clean and constant availability for service. After using the tool, before folding in a storage place, always carefully wipe its surface pure dry rags, deleting traces of a dirt, greasing and the rests of metal particles. Never leave the tool scattered. After end of works attentively check space under a cowl and under the car on presence of the forgotten tool.

    For storage of such tool as screw-drivers, flat-nose pliers, hammers, etc., the tool comb fixed in a convenient place on a wall of garage is ideally suited. Sets of wrenches and replaceable face heads should be stored in metal boxes. The precision measuring tool should be stored in inaccessible to influence of corrosion, dry and pure places.

    Always it is necessary to pay attention to a condition of a working surface of the tool. The shock part бойка a hammer in the course of use is subject расклепыванию, screw-drivers lose in due course sharpening of the stings. Do not stint to give a few time and attention to that by means of an emery paper or a file to remove расклепы and to put in order cutting edges. It is irreversible the worn out or damaged tool in due time replace.

    At careful leaving the tool is capable to serve belief and the truth during very long term.

    The workplace equipment

    Speaking about the tool, it is necessary to recollect the workplace equipment. If carrying out of more serious work, than simple maintenance service of a vehicle is necessary, it is necessary to take care of preparation of the suitable worker of a platform.

    It is necessary to recognise that many motorists are compelled to make dismantle of the engine and other similar works far not in the conditions of garage or a workshop. However in any case the important requirement is roof or awning presence.

    Whenever possible, any procedures on dismantling of parts of systems of the car should be made on a pure workbench with an equal working surface, or a strong table of convenient height. The workbench should be necessarily equipped by a vice with disclosing of sponges to 100 mm and with soft overlays on sponges.
    As already it was mentioned above, on a working platform the pure dry place for storage of the tool, lubricant and cleaning liquids, шпаклевок, paint and varnish materials, etc. should be equipped

    It is necessary to notice that absolutely necessary tool is the electrodrill, hence, the working platform should be equipped by the power supply for its connection. Presence of a drill with a cartridge to 9.5 mm and a set of qualitative drills appreciably will facilitate carrying out of many procedures.

    At last, on a workplace always there should be a sufficient stock of old newspapers and pure, not ворсящейся the rags, intended for gathering of the spilt liquids and rubbing of a working platform, the tool and car details.

    It is necessary to hand over the fulfilled working liquids in the centres on recycling in tight container.

    Never make any works on the barefaced painted surface кузовных car panels, use protective overlays on wings, or, at the worst, cover the polished surfaces with old blankets.