Audi A4, S4

Since 2000 of release

Repair and car operation



Audi A4, S4
+ Introduction
+ Controls and receptions of safe operation
+ Current leaving and service
- The engine
   Specifications
   Removal and installation of the top cover of the engine / the bottom protection of an impellent compartment/stretcher
   Compression check in engine cylinders, revealing of leaks
   Check of the engine by means of the vacuum gauge
   - 4-cylinder petrol engines
      The general data
      Removal and installation of a gear belt
      Removal and installation of a head of cylinders
      Removal and installation of a belt of a drive of auxiliary units
   + 6 and 8-cylinder petrol engines
   + 4-cylinder diesel engines
   + 6-cylinder diesel engines
   + System of greasing of 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



Removal and installation of a gear belt

The petrol engine of 1.6 l ALZ

Drive ГРМ. The petrol engine of 1.6 l ALZ

1 — the Rotary lock. For opening turn counter-clockwise
2 — the Top cover of a gear belt
3 — the Bolt, 100Нм
4 — the Wheel of a gear belt
5 — the Combined screw, 10Нм
6 — the Back cover of a gear belt
7 — the Screw with internal шестигранником, 15Нм
8 — the Sealing ring. Necessarily replace. At installation moisten with cooling liquid G12
9 — the Pump of a cooling liquid
10 — the Gear belt. If the belt which was in work is applied, before removal mark a direction of its rotation with a chalk or a felt-tip pen. Do not bend a belt

11 — the Cogwheel of a cranked shaft. Attention: On an adjoining surface between a cogwheel and cranked shaft should not be oils
12 — the Bolt, 90Нм + 90 . Necessarily replace. The carving and a basic surface should not have some greasing
13 Bottom cover of a gear belt
14 — Bolts, 10Нм
15 — the Pulley of a cranked shaft / демпфер крутильных fluctuations
16 — the Screw, 25Нм
17 Central cover of a gear belt
18 — the Tension roller
19 — the Washer
20 — the Nut, 20Нм

Removal

 PERFORMANCE ORDER

  1. Establish the forward panel in position for service, address to Section Installation of the forward panel in position for maintenance service.
  1. Remove the top cover of the engine.
  1. Remove клиновой a belt, address to Section Removal and installation of a belt of a drive of auxiliary units.
  1. Disconnect a tension element клинового a belt.

Sketch adjusting position of the top cover of a gear belt, in particular, in a transition place to the central cover.

  1. Turn a rotary lock counter-clockwise (an arrow on fig.) so that шлиц the screw was in vertical position.
  1. Disconnect the top cover of a gear belt. For this purpose wring out upwards lock pads of a clip (the marksman on fig.).
  1. Remove the top cover of a gear belt.
  1. Tighten a lay brake and establish a check point in neutral position.
  1. Establish the engine in ВМТ the piston of the first cylinder. For this purpose turn a cranked shaft for the central bolt of fastening of a cogwheel in a direction of rotation of the engine, i.e. clockwise so that labels on a wheel of a camshaft and on cranked to a shaft have coincided.
  1. Manual a check point: labels ВМТ on a flywheel and to leaders a disk Should coincide.
  1. АТ: Label ВМТ should be at the left edge of a window (the marksman on an accompanying illustration).
  1. Turn away screws of fastening of a pulley of a cranked shaft and take out a pulley.
  1. Disconnect the central and bottom covers of a gear belt (arrow) and take out them.
  1. Put a chalk or a felt-tip pen on a gear belt an arrow specifying a direction of rotation.
  1. Turn on клеммную a nut (20) fastenings of a tension roller (18). Turn a tension roller by means of tool T10020 clockwise and thus ослабьте a tension of a gear belt, Drive ГРМ see. The petrol engine of 1.6 l ALZ and an accompanying illustration.
  1. Remove a gear belt.

Installation (adjustment of phases timing)

If during repair carrying out the gear belt acts in film only from a camshaft wheel, adjustment of phases timing is necessary.

At turn of a camshaft without a gear belt it is not necessary to establish any cylinder in position ВМТ. There is a danger of damage of valves and-or the bottoms of pistons.

 PERFORMANCE ORDER

  1. Turn cogwheels so that labels on a wheel of a camshaft and a back cover of a gear belt, and also a label of a wheel of a cranked shaft and the bottom cover of a gear belt have coincided. For this purpose quickly establish a wheel of a cranked shaft.
  2. Put on a gear belt a wheel of a cranked shaft.

Observe a direction of its rotation.

  1. Establish into place the central and bottom covers of a gear belt and fix them.
  2. Establish a wheel of a cranked shaft so that the aperture on a wheel has coincided with a ledge on a wheel of a cranked shaft. In this position fix a wheel the moment 25Нм.
  3. Put on a gear belt a tension roller and a camshaft wheel.

Tension of a gear belt

The engine should be heated-up to temperature not above hand temperature.

 PERFORMANCE ORDER

  1. Check up, whether labels on a wheel of a camshaft and a back cover of a gear belt, and also on a wheel of a cranked shaft and the bottom cover of a gear belt coincide.
  1. Before a tension of a gear belt turn a tension roller on the clown by means of tool T10020 five times in both directions against the stop.
  1. Turn the clown tool T10020 counter-clockwise (an arrow direction on an illustration) against the stop.
  1. Slowly pull a gear belt so that a label (1) and the index (2) stood opposite each other. If necessary, take advantage for the control of a mirror.
  1. Keeping a tension roller in this position, tighten a nut of fastening by the moment 20Нм.
  1. Turn further a cranked shaft on two turns in a direction of rotation of the engine so that the engine has stopped in ВМТ the first cylinder. It is thus important, that the last 45 rotation was made without a stop.
  1. Once again check up a tension of a gear belt: the Index and a label should be opposite each other.

The further installation

 PERFORMANCE ORDER

  1. Fix the top cover of a gear belt. Turn a rotary lock clockwise so that шлиц the screw has occupied horizontal position.
  2. Fix tightening an element клинового a belt the moment 25Нм.
  3. Put on клиновой a belt, address to Section Removal and installation of a belt of a drive of auxiliary units.
  4. Establish the top cover of the engine, address to corresponding Section.
  5. Establish the forward panel in position for service, address to Section Installation of the forward panel in position for maintenance service.

Petrol engines of 1.8 and 2.0 l (AVJ, BFB, ALT)

Drive ГРМ. Petrol engines of 1.8 and 2.0 l (AVJ, BFB, ALT)

1 — the Bottom cover of a gear belt
2 — the Bolt, 10Нм. It is rolled on hermetic
3 — the Central cover of a gear belt. For removal turn away the tension device клинового a belt
4 — the Top cover of a gear belt
Engines AVJ, BFB: At installation accurately connect to the central cover of a gear belt.
Engine ALT: 10Нм.
5 — the Gear belt
6 — the Directing roller
7 — Klemmnaja a nut, 27Нм
8 — the Bolt, 65Нм
9 — the Wheel of a camshaft of final valves

10 — the Tension roller
11 — the Washer
12 — the Device of a tension of a gear belt
13 — the Sealing ring. Necessarily replace At installation moisten with a cooling liquid
14 — the Pump of a cooling liquid
15 — the Bolt, 15Нм
16 — the Wheel of a gear belt of a cranked shaft. On an adjoining surface between a cogwheel and cranked shaft should not be oils
17 — the Bolt, 90Нм + 90 . Necessarily replace. Do not grease
18 — the Bolt, 15Нм
19 — the Bolt, 25Нм

Position of a wheel of a camshaft. The narrow wall of a wheel of a camshaft shows outside of (arrow), and label ВМТ of the first cylinder is visible in front

Removal and installation procedures are similar to the petrol engine of 1.6 l. Therefore differences are described only.

Removal

The tension element of the device of a tension of a gear belt () has oil демпфирование and can be compressed only slowly and under the influence of uniform loading. The excessive effort at compression can lead to damage of a tension roller.

 PERFORMANCE ORDER

  1. Insert against the stop a face key in шестигранное an aperture of a tension roller and turn a tension roller counter-clockwise (on an arrow on an accompanying illustration) so that the tension device could be fixed plates HAZET 2588-2.

Turn a tension roller, without putting excessive effort.

Insert against the stop a face key so that at turn not to damage шестигранник at a tension roller.

The tension element of a gear belt has oil демпфирование. To press it it is necessary slowly and in regular intervals.

It is not necessary to bend a persistent pad () the lever of the clown.

  1. For a tension of a gear belt release a nut (1) tension rollers and turn the clown key HAZET 2587-1 in an arrow direction.
  1. If the gear belt which was in work is established, note on it a chalk or a felt-tip pen a rotation direction.
  1. Remove a gear belt.

Installation (adjustment of phases timing)

Installation is carried out to the similarly same procedure for the petrol engine of 1.6 l.

Tension of a gear belt

If the tension element of a gear belt is completely put forward, it is necessary for turning in the established position back together with a tension roller. This process can proceed till 5 minutes. The excessive appendix of effort at compression can lead to damage of a tension roller.

 PERFORMANCE ORDER

  1. If the tension element of a gear belt is completely put forward press a tension roller a face key counter-clockwise so that the piston of the tension device could be fixed by lock plates HAZET 2588-2.

Turn a tension roller in regular intervals, without making considerable effort.

It is not necessary to bend a persistent nouse () the lever of the clown.

  1. Turn the clown key HAZET 2587-1 counter-clockwise so that lock plate HAZET 2588-2 could be extended.
  1. Then turn the clown clockwise so that a drill in the size and = 8 mm could pass between the tension lever and the case of the tension device.
  1. Keeping in this position the clown, tighten a nut (1) fastenings of a tension roller. After that remove a key for a nut inhaling.
  1. Turn the engine on two turns for the central bolt of a cranked shaft (clockwise) and again establish it in ВМТ the ignition moment.
  1. Check up a drill the size () between the tension lever and the case of the tension device. The specified size should make 6 10 mm.
  1. If the size () is less, ослабьте a belt, compress a tension element and again pull a gear belt.
  1. If the size () will reach, finish installation process.

The petrol engine of 2.0 l AWA

Drive ГРМ. The petrol engine with direct injection of 2.0 l AWA

1 — the Bottom cover of a gear belt
2 — the Bolt, 10Нм. It is rolled with means for fixing
3 — the Central cover of a gear belt. For removal turn away the tension device клинового a belt
4 — the Top cover of a gear belt. At installation accurately connect to the central cover of a gear belt and fix the moment 10Нм
5 — the Bolt, 10Нм
6 — the Gear belt
7 — Klemmnaja a nut, 27Нм
8 — the Bolt, 65Нм
9 — the Wheel of a camshaft of final valves
10 — the Holder of a directing roller
11 — the Washer
12 — the Lock plate of a tension roller
13 — the Bolt, 9Нм
14 — the Directing roller

15 — the Bolt, 40Нм
16 — the Sealing ring. Necessarily replace. At installation moisten with a cooling liquid
17 — the Pump of a cooling liquid
18 — the Bolt, 15Нм
19 — the Bolt, 40Нм
20 — the Bolt, 15Нм
21 — the Lock plate демпфера the tension device of a belt
22 — the Bolt, 16Нм
23 — Dempfer of the tension device of a belt
24 — the Directing roller
25 — the Bolt, 25Нм
26 — the Wheel of a gear belt of a cranked shaft. On an adjoining surface between a cogwheel and cranked shaft should not be oils
27 — the Bolt, 90Нм + 90 . Necessarily replace. Do not grease

Removal

 PERFORMANCE ORDER

  1. Removal and installation are similar to the same procedures for the petrol engine of 1.6 l. Therefore here differences (address to an illustration above) are described only.
  1. Turn away fastening bolts above and uncover a gear belt. Instructions: For simplification of the subsequent installation mark position in a transition place to the central cover of a gear belt.

The tension element of the device of a tension of a gear belt () has oil демпфирование and can be compressed only slowly and under action of uniform loading. The excessive effort at compression can lead to damage of a tension roller.

  1. Press a tension roller a face key clockwise (an arrow on an accompanying illustration) so that the piston it was possible to fix the piston of the tension device a corresponding pin, for example, T40011.

Turn a roller in regular intervals, without making excessive effort. If the former gear belt is established, mark with a chalk or a felt-tip pen on board of its rotation.

  1. Turn on the holder with a directing roller (1). The arrow specifies fastening bolts демпфера the tension device of a belt.
  1. Remove a gear belt.
 

Installation (adjustment of phases timing)

Installation is carried out to the similarly same procedure for the petrol engine of 1.6 l.

As a result establish and fix the holder with a directing roller and a remote washer (11), address to an illustration Drive ГРМ. The petrol engine with direct injection of 2.0 l AWA.

Tension of a gear belt

 PERFORMANCE ORDER

  1. Turn a tension roller a face key after an hour hand direction so that it was possible to take out a lock pin.
  1. Slowly turn a tension roller a face key counter-clockwise and thus pull a gear belt.

If the tension element of a gear belt is completely put forward, it is necessary for turning in the established position back together with a tension roller. This process can proceed till 5 minutes. The excessive appendix of effort at compression can lead to damage of a tension roller.

  1. If the tension element of a gear belt is completely put forward press a tension roller a face key counter-clockwise so that the piston of the tension device could be fixed by a corresponding pin, for example, Т40011.

Turn a tension roller in regular intervals, without making considerable effort