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
+ 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
   Specifications
   Removal and check point installation
   Check of level of oil in a manual check point
   Adjustment of a drive of a gear change
   Check of adjustment of the lever of a gear change
+ Automatic transmission
+ Coupling, power shafts and differential
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment



Removal and check point installation

For removal of a check point the car should be lifted on necessary height. Besides, the garage lift is necessary for carrying out of the specified operation. Described below operation concern a 5-step manual check point of cars with a forward drive.

Removal

 PERFORMANCE ORDER

  1. Disconnect a negative cable (-) the storage battery.

Observe instructions Replacement of the storage battery Has undressed.

 
  1. Remove engine covers, address to Section Removal and installation of the top cover of the engine / the bottom protection of an impellent compartment/stretcher.
  2. Turn out fastening nuts турбокомпрессора.
  3. Turn out all connecting bolts the engine/kpp which are accessible from above.
  1. Establish to a traverse and застропьте the engine.

The pipeline of giving of fuel is under pressure! Before opening шлангового connections cover with its thick rag. Then remove pressure by a cautious detachment of a hose.

  1. Lift and establish the car on supports.
  2. Models with lay heating: Turn out bolts of fastening of an exhaust pipe of lay/additional heating to the bottom cover of an impellent compartment.
  3. Turn away bolts of fastening and remove the holder of the bottom cover of an impellent compartment (marksman).
  4. Remove the heat-shielding screen over the right power shaft.
  5. Turn away bolts of fastening and remove the left and right covers (arrow) of an exhaust pipe.
  1. Remove a forward cross-beam of the tunnel (1) (arrows on an accompanying illustration).
  1. Remove a reception pipe (3) with клеммной plugs (2), address to the Part of System of release and decrease in toxicity of the fulfilled gases. turbocharger.
  2. Remove the heat-shielding screen (4) over release system.
  1. Turn out the bottom connecting bolts the engine/kpp (arrows on an accompanying illustration).
  1. Disconnect on flanges both power shafts and adhere them on a wire, address to Section Removal and power shaft installation.

Watch that at отворачивании not to damage a sheeting of power shafts.

  1. Remove a starter, thus a cable do not disconnect from a starter. Fix a starter on a wire to a body.
  2. On HUNDRED check points it is fixed and supported by lift V.A.G. If the specified lift available is not present, bring under a check point the garage lift with a wide wooden lining and slightly raise a check point.
  1. Turn out at first bolts (2) and then bolts (3) on a tunnel cross-beam. Turn out both nuts (4), remove a tunnel cross-beam.
  1. Cautiously lower the lift with the engine/kpp so that it was visible to a check point. Clean the lift.
  1. Turn out a bolt () bar fastenings to a check point and disconnect the hinge of switching from an axis.
  1. Disconnect pushing bar having turned away the screw with internal шестигранником () at a check point.
  1. Take out a socket (1) if it is available, from the holder (the marksman on an accompanying illustration). Disunite a socket and take aside a cable.
  1. Disunite a socket () the gauge of a tachometre and () a backing lantern at the left at a check point.
  1. Disconnect the gauge of number of turns of the engine if it is available, at the left at a check point (the marksman on an accompanying illustration) and take him aside.
  1. Turn out the bottom connecting bolts the engine/kppp, but not bolts () and ().
  1. Bring under a check point the corresponding lift and fix a check point юстировочной a plate.
  2. Turn out the remained connecting bolts the engine/kpp () and ().
  3. Wring out a check point from the engine and slowly lower downwards.

Installation

At replacement of any details established on a check point or bolts keep in mind the following: the check point Case is executed from a magnesian or aluminium alloy. According to it those or other established details, as for example a cover, and bolts are applied. If details КППП from aluminium are established on the case from a magnesian alloy last will be exposed to corrosion. It concerns also fastening bolts фланцевого connections the engine/kpp. They have a special covering for the case of a check point from a magnesian alloy. A sign of a check point from a magnesian alloy is the inscription Mg AL 9 Zn 1 from the bottom party of a check point and around a stopper for filling with oil.

 PERFORMANCE ORDER

  1. Before installation check up coupling, address to Section Removal, installation and coupling check.
  2. Clear шлицевое connection of a primary shaft and slightly grease with greasing MoS 2 AUDI-G000100.

The conducted disk of coupling should come easily on a primary shaft of a check point. Surpluses of greasing clean.

  1. Clear all carving apertures in which self-stopped bolts, by a tap from the hermetic rests are rolled. Self-stopped bolts and nuts necessarily replace with the new.
  2. Check up deterioration of the bearing of deenergizing of coupling, if necessary, replace. If on the plastic bearing there are flutes more deeply 0.5 mm, it is necessary to replace the bearing.
  3. Grease an adjoining surface of a pusher at the lever of the bearing of deenergizing of coupling with copper greasing, for example, Z381 351 TE.
  4. Check up, whether aligning plugs for centering of connection the engine/kpp in the block of cylinders stand still, if necessary, insert.
  5. Watch correct position of an intermediate plate at the engine if that is available.
  6. Enter horizontally a check point into coupling. If at installation the primary shaft of a check point does not enter into a conducted disk, turn a hand a shaft for a flange.
  7. Establish the working cylinder of a drive of coupling with the holder. By means of mount enter the cylinder so that it is possible to insert a fastening bolt easily. Tighten a bolt the moment 25Нм.
  8. Establish into place a starter, address to Section Removal and starter installation.
  1. Screw the bottom bolts () for fastening of the engine from a check point and () for starter fastening.
  1. Lower the block the engine/kpp.
  2. Tighten the top bolts of fastening the engine/kpp the established moment.
  1. Fix a tunnel cross-beam to a support of a check point (1).
  2. Fix a tunnel cross-beam to a body. Screw at first a bolt (2) then a bolt (3).
  1. Tighten from below 3 bolts of fastening of the engine to a check point the moment 45Нм.
  1. Establish into place draught of a gear change. Fix its moment 20Нм.
  2. Establish pushing bar and fix its moment 40Нм.
  1. Establish power shafts and a guard of shaft, address to Section Removal and power shaft installation.
  2. Join all earlier disunited sockets.
  3. At a lining of electric connections watch that all collars which removed or have been cut off at dismantle, have been established on the former places.
  4. Establish the heat-shielding screen of an exhaust pipe. Establish a reception pipe and establish release system, address to Section Removal and installation of system of release. Replacement of the central, additional muffler, a trailer pipe.
  5. Check up adjustment of a drive of a gear change, address to Section Adjustment of a drive of a gear change.
  6. Check up oil level in a check point, address to Section Check of level of oil in a manual check point.
  7. Attach negative (-) a cable of the storage battery.

Observe instructions Replacement of the storage battery Has undressed.

The moments of a tightening of carving connections

Bolts of fastening the engine/kpp. Engines 1.6, 1.8, 1.9, 2.0 l


Position

Bolt

The tightening moment

Engines 1.6, 2.0 l

1, 3, 4

М12 х 75

65Нм

2

М12 х 90

65Нм

5, 11

М12 х 110

65Нм

7-10

М10 х 45

45Нм

11 М12 х 130 65Нм

AND

Aligning plugs

Engines 1.8, 1.9 l:

1, 3, 4 М12 х 67 65Нм
2, 6 М12 х 90 65Нм
5, 11 М12 х 110 65Нм
7-11 М10 х 45 45Нм

AND

Aligning plugs


Bolts of fastening the engine/kpp. Engines 2.4, 3.0 l


Position

Bolt

The tightening moment

The engine of 2.4 l

1, 9, 10, 11

М10 х 45

45Нм

2

М10 х 135

65Нм

3

М12 х 130

65Нм

4, 5, 6

М12 х 67

65Нм

7 М12 х 90 65Нм
8 М12 х 80 65Нм
AND Aligning plugs
The engine of 3.0 l    
1, 9, 10, 11 М10 х 60 45Нм
2 М10 х 150 65Нм
3 М12 х 130 65Нм
4 М12 х 80 65Нм
5, 6, 8 М12 х 90 65Нм
7 М10 х 100 45Нм
AND Aligning plugs

Bolts of fastening an engine/stabilizer support

1 — the Stabilizer (2) to the console of a support of the engine 25Нм
3 — an engine Support to the console of a support of the engine 25Нм

Nuts (1) are necessarily replaced.