Audi A4, S4

since 2000 release

Repair and operation of the car



Audi A4, S4
+ Introduction
+ Governing bodies and methods of safe operation
+ Current leaving and service
- Engine
   Specifications
   Removal and installation of the top cover of the engine / lower protection of a motive compartment / stretcher
   Check of a compression in engine cylinders, identification of leaks
   Check of the engine by means of the vacuum gage
   - 4-cylinder petrol engines
      General information
      Removal and installation of a gear belt
      Removal and installation of a head of cylinders
      Removal and installation of a belt of the drive of auxiliary units
   + 6-and 8-cylinder petrol engines
   + 4-cylinder diesel engines
   + 6-cylinder diesel engines
   + engine Lubrication system
+ Cooling systems, heating and air conditioner
+ Power supply systems, release and decrease in toxicity of the fulfilled gases
+ Systems of electric equipment of the engine
+ Manual box of gear shifting
+ Automatic transmission
+ Coupling, power shafts and differential
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment






Removal and installation of a gear belt

Petrol engine of 1.6 l of ALZ

GRM drive. Petrol engine of 1.6 l of ALZ

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

11 — the Cogwheel of a cranked shaft. Attention: On an adjacent surface between a cogwheel and cranked shaft should not be oils
12 — the Bolt, 90nm + 90 °. Surely replace. The carving and a basic surface should not have greasing
13 — the Lower cover of a gear belt
14 — Bolts, 10nm
15 — the Pulley of a cranked shaft / damper of tortional fluctuations
16 — the Screw, 25nm
17 — the Central cover of a gear belt
18 — the Tension roller
19 — the Washer
20 — the Nut, 20nm

Removal

 PERFORMANCE ORDER

  1. Install the forward panel in situation for service, address to the Section Installation of the Forward Panel in situation for maintenance.
  1. Remove the top cover of the engine.
  1. Take off maple a belt, address to the Section Removal and installation of a belt of the drive of auxiliary units.
  1. Disconnect a tension element of a maple belt.

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

  1. Turn a rotary lock counterclockwise (an arrow on rice. A) so that vents of the screw was in vertical situation.
  1. Disconnect the top cover of a gear belt. For this purpose wring out lock pads of a clip (the shooter on rice up. C).
  1. Remove the top cover of a gear belt.
  1. Tighten the parking brake and establish a check point in neutral situation.
  1. Install the engine in VMT of the piston of the first cylinder. For this purpose turn a cranked shaft for the central bolt of fastening of a cogwheel in the direction of rotation of the engine, i.e. clockwise so that tags on a wheel of a camshaft and on cranked to a shaft coincided.
  1. Manual check point: VMT tags on a flywheel and the leader a disk have to coincide.
  1. AT: The tag of VMT has to be at the left edge of a window (the shooter on an accompanying illustration).
  1. Unscrew screws of fastening of a pulley of a cranked shaft and take out a pulley.
  1. Disconnect the central and lower covers of a gear belt (arrow) and take out them.
  1. Apply with chalk or a felt-tip pen on a gear belt to the shooter, specifying the direction of rotation.
  1. Turn off a terminal nut (20) fastenings of a tension roller (18). Turn a tension roller by means of the T10020 tool clockwise and thus weaken a tension of a gear belt, see the GRM Drive. Petrol engine of 1.6 l of ALZ and accompanying illustration.
  1. Take off a gear belt.

Installation (adjustment of phases of gas distribution)

If during repair the gear belt is removed only from a camshaft wheel, adjustment of phases of gas distribution is necessary.

At turn of a camshaft without gear belt it is not necessary to install any cylinder in situation VMT. There is a danger of damage of valves and/or the bottoms of pistons.

 PERFORMANCE ORDER

  1. Turn cogwheels so that tags on a wheel of a camshaft and a back cover of a gear belt, and also a tag of a wheel of a cranked shaft and the lower cover of a gear belt 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 the direction of its rotation.

  1. Establish into place the central and lower covers of a gear belt and fix them.
  2. Establish a wheel of a cranked shaft so that the opening on a wheel coincided with a ledge on a wheel of a cranked shaft. Fix a wheel in this situation the moment 25nm.
  3. Put on a gear belt a tension roller and a wheel of a camshaft.

Tension of a gear belt

The engine has to be heated-up up to the temperature not higher than temperature of hand.

 PERFORMANCE ORDER

  1. Check, whether tags 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 lower cover of a gear belt coincide.
  1. Before a tension of a gear belt turn a tension roller on the clown by means of the T10020 tool five times to both directions against the stop.
  1. Turn the clown the T10020 tool counterclockwise (the direction of an arrow on an illustration) against the stop.
  1. Slowly pull a gear belt so that a tag (1) and the index (2) stood opposite to each other. If necessary, use a mirror for control.
  1. Holding a tension roller in this situation, tighten a fastening nut the moment 20nm.
  1. Turn further a cranked shaft on two turnovers of the direction of rotation of the engine so that the engine stopped in VMT of the first cylinder. Thus it is important that the last 45 ° rotation was made without stopping.
  1. Double-check a tension of a gear belt: The index and a tag have to be opposite to each other.

Further installation

 PERFORMANCE ORDER

  1. Fix the top cover of a gear belt. Turn a rotary lock clockwise so that vents of the screw reached horizontal position.
  2. Fix tightening an element of a maple belt the moment 25nm.
  3. Put on maple a belt, address to the Section Removal and installation of a belt of the drive of auxiliary units.
  4. Establish the top cover of the engine, address to appropriate section.
  5. Install the forward panel in situation for service, address to the Section Installation of the Forward Panel in situation for maintenance.

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

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

1 — the Lower cover of a gear belt
2 — the Bolt, 10nm. It is rolled on sealant
3 — the Central cover of a gear belt. For removal unscrew the device of a tension of a maple belt
4 — the Top cover of a gear belt
AVJ, BFB engines: At installation accurately connect to the central cover of a gear belt.
ALT engine: 10nm.
5 — the Gear belt
6 — the Directing roller
7 — the Terminal nut, 27nm
8 — the Bolt, 65nm
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. Surely replace At installation moisten with cooling liquid
14 — the Pump of cooling liquid
15 — the Bolt, 15nm
16 — the Wheel of a gear belt of a cranked shaft. On an adjacent surface between a cogwheel and cranked shaft should not be oils
17 — the Bolt, 90nm + 90 °. Surely replace. Do not grease
18 — the Bolt, 15nm
19 — the Bolt, 25nm

Provision of a wheel of a camshaft. The narrow wall of a wheel of a camshaft shows outside (arrows), and the tag of VMT of the first cylinder is visible in front

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

Removal

The tension element of the device of a tension of a gear belt (And) has oil damping and can contract 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 into a six-sided opening of a tension roller and turn a tension roller counterclockwise (on an arrow on an accompanying illustration) so that the device of a tension could be fixed HAZET 2588-2 plates.

Turn a tension roller, without using the excessive efforts.

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

The tension element of a gear belt has oil damping. It is necessary to press it slowly and evenly.

It is not necessary to bend a persistent pad (And) the clown's lever.

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

Installation (adjustment of phases of gas distribution)

Installation is carried out similar to the 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 needs to be turned in the established situation together with a tension roller back. This process can proceed till 5 minutes. The excessive application 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 counterclockwise so that the piston of the tension device could be fixed by lock plates of HAZET 2588-2.

Turn a tension roller evenly, without making considerable effort.

It is not necessary to bend a persistent nose (And) the clown's lever.

  1. Turn the clown HAZET 2587-1 key counterclockwise so that the lock plate of HAZET 2588-2 could be extended.
  1. Then turn the clown clockwise so that the drill the size and = could pass 8 mm between the tension lever and the case of the tension device.
  1. Holding in this situation the clown, tighten a nut (1) fastening 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 ignition moment VMT.
  1. Check a drill the size (and) between the tension lever and the case of the tension device. The specified size has to make 6 ÷ 10 mm.
  1. If the size (and) is less, weaken a belt, squeeze a tension element and again pull a gear belt.
  1. If the size (and) is reached, finish installation process.

Petrol engine of 2.0 l of AWA

GRM drive. The petrol engine with direct injection of 2.0 l of AWA

1 — the Lower cover of a gear belt
2 — the Bolt, 10nm. It is rolled with means for fixing
3 — the Central cover of a gear belt. For removal unscrew the device of a tension of a maple 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 10nm
5 — the Bolt, 10nm
6 — the Gear belt
7 — the Terminal nut, 27nm
8 — the Bolt, 65nm
9 — the Wheel of a camshaft of final valves
10 — the Holder of the directing roller
11 — the Washer
12 — the Lock plate of a tension roller
13 — the Bolt, 9nm
14 — the Directing roller

15 — the Bolt, 40nm
16 — the Sealing ring. Surely replace. At installation moisten with cooling liquid
17 — the Pump of cooling liquid
18 — the Bolt, 15nm
19 — the Bolt, 40nm
20 — the Bolt, 15nm
21 — the Lock plate of a damper of the tension device of a belt
22 — the Bolt, 16nm
23 — the Damper of the tension device of a belt
24 — the Directing roller
25 — the Bolt, 25nm
26 — the Wheel of a gear belt of a cranked shaft. On an adjacent surface between a cogwheel and cranked shaft should not be oils
27 — the Bolt, 90nm + 90 °. Surely 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 only differences are described (address to an illustration above).
  1. Turn off fastening bolts above and uncover a gear belt. Instruction: For simplification of the subsequent installation mark situation in a place of transition to the central cover of a gear belt.

The tension element of the device of a tension of a gear belt (And) has oil damping and can contract 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 the corresponding pin, for example, of T40011.

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

  1. Turn off the holder with the directing roller (1). The arrow specified bolts of fastening of a damper of the tension device of a belt.
  1. Take off a gear belt.
 

Installation (adjustment of phases of gas distribution)

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

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

Tension of a gear belt

 PERFORMANCE ORDER

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

If the tension element of a gear belt is completely put forward, it needs to be turned in the established situation together with a tension roller back. This process can proceed till 5 minutes. The excessive application 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 counterclockwise so that T40011 could be recorded the piston of the tension device by the corresponding pin, for example.

Turn a tension roller evenly, without making considerable effort












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