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
   + 6-and 8-cylinder petrol engines
   - 4-cylinder diesel engines
      General information
      Removal and installation of a gear belt, engines of 1.9 l (AVB, AWX, AVF)
      Natyazhitel of a belt with damping by friction
      Removal and installation of a head of cylinders, diesel engines of 1.9 l (AVB, AWX, AVF)
      Removal and installation of a belt of the drive of auxiliary units
   + 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, engines of 1.9 l (AVB, AWX, AVF)

The description belongs to the drive a gear belt with hydraulic damping of a tension roller. Its sign is existence of a damper (12). Instructions for the drive are provided by a gear belt with the tension roller having damping by friction in the end of the Head.

GRM Zubchatoremyonny drive. Diesel engines of 1.9 l (AVB, AWX, AVF)

1 — the Cover of a gear belt top. For removal remove an air duct to the forward panel. At installation accurately connect to the central cover of a gear belt
2 — the Gear belt
3 — the Nut, 20nm + 45 °
4 — the Tension roller
5 — the Bolt, 100nm
6 — the Bolt, 25nm
7 — a camshaft Wheel. Mark situation
8 — the Nave with a gear wheel for the Hall sensor
9 — the Bolt, 10nm. It is rolled on sealant
10 — the Cover of a gear belt, back
11 — the Rubber plug. In the presence of damages replace
12 — the Damper of a natyazhitel of a belt
13 — the Directing roller
14 — the Pump of cooling liquid

15 — the Wheel of a gear belt of a cranked shaft. On an adjacent surface between a wheel of a gear belt and a cranked shaft there should not be an oil. Installation is possible only in one situation
16 — the Bolt *, 120nm + 90 °. Not to grease
17 — the Bolt, 15nm
18 — the Bolt, 20nm
19 — the Cover of a gear belt lower
20 — the Wheel of a cranked shaft (a damper of tortional fluctuations). Installation is possible only in one situation, openings are displaced
21 — the Bolt *, 10nm + 90 °
22 — the Cover
23 — the Cover of a gear belt central. For removal remove the top cover of a gear belt and disconnect the device of a tension of a maple belt
*) Surely replace.

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. Take out the index of level of oil (1) of the directing pipe.
  1. Disconnect covers and turn off the nuts (arrow) lying under them.
  2. Remove the top cover of the engine.
  3. Remove the damper lying under it.
  4. Again insert against the stop the index of level of oil.
  5. Take off maple a belt, address to the Section Removal and installation of a belt of the drive of auxiliary units.
  1. Holding a fan pulley with the viscous coupling by means of the tool 3212, turn off it a face key on 8 mm (1) from the holder.
  1. Remove the fan with the viscous coupling and put it in a fan casing.
  2. Remove the generator and take out the fan with the viscous coupling from a casing, address to the Section Removal and installation of the generator.
  1. Turn out screws (1) and (2) and remove the device of a tension of a maple belt.
  1. Remove the top cover of a gear belt.
  1. Turn out screws (3) and uncover (2).
  1. Take aside the electromagnetic valve of adjustment of pressure of pressurization (1).
  1. Uncover at a pulley of a cranked shaft (a damper of tortional fluctuations) and turn off a pulley.

For an otvorachivaniye and fastening of a pulley hold it a cap key for the central bolt.

  1. Disconnect the central and lower covers of a gear belt (an arrow on an accompanying illustration).

The cranked shaft is allowed to be turned only in the direction of rotation of the engine, i.e. clockwise. The cranked shaft by a key for the central bolt is turned.

  1. Turn a cranked shaft and establish it in position VMT of the first cylinder. Thus the interval between pads (1) on a rotor of the sensor of a camshaft has to lie against marking "4Z" (2) on a back cover of a gear belt.

    On an accompanying illustration for descriptive reasons the wheel is shown without gear belt.


  1. Record a nave HAZET 2588-3 finger.

Instead of the specified finger it is possible to apply a mandrel with a diameter of 6 mm.

  1. Record a pulley of a cranked shaft HAZET 2588-1 finger. For this purpose insert the special tool (a stopper of a cranked shaft) from an end face of a wheel of a gear belt into its gear wreath.

Tags on a cogwheel of a cranked shaft (2) and the fixing tool (1) have to be opposite to each other. Thus the pin of the tool has to enter an opening of a sealing flange. If such tool available is not present, apply VMT tag on a sealing flange.

  1. Turn off bolts of fastening (arrow) so that a wheel of a camshaft it was turned in oblong openings.
  1. Insert a face key against the stop into a six-sided opening of a tension roller and turn a tension roller counterclockwise (the direction of an arrow on an accompanying illustration) so that the device of a tension could be fixed by a lock level of HAZET 2588-2.

The face key is inserted against the stop in order that it was not damaged at turn of a tension roller.

The tension element of a gear belt has oil damping and it is necessary to press it evenly, without application of considerable efforts.

  1. If the gear belt which was in work is established, note on it chalk or a felt-tip pen the direction of rotation.
  2. Turn off a nut of fastening of a tension roller.
  1. Turn out bolts (arrows on an accompanying illustration) the tension device of a gear belt and remove the tension device.
  1. Take off a gear belt.

Installation (adjustment of phases of gas distribution)

 PERFORMANCE ORDER

  1. Check, whether HAZET 2588-3, and a cranked shaft HAZET 2588-1 stopper are recorded a camshaft by a finger, and also whether the device of a tension of a gear belt is fixed by a lock plate of HAZET 2588-2.

Adjusting works with a gear belt are allowed to be performed only on the cold engine.

At a provorachivaniye of a cranked shaft its stop at position of any piston in VMT is not allowed. Thus there is a danger of damage of valves and/or the bottoms of pistons. If necessary, turn off a cranked shaft back on a corner 90 °.

  1. Screw bolts by hand.

The wheel of a camshaft has to rotate and not overturn.

  1. Turn a camshaft wheel in its oblong openings against the stop.
  2. Put on a gear belt a camshaft wheel, a tension roller, a wheel of a cranked shaft and in the last turn on a wheel of the pump of cooling liquid.
  3. Install the device of a tension of a gear belt.

Tension of a gear belt

 PERFORMANCE ORDER

  1. Turn the clown the HAZET 2587-1 tool counterclockwise against the stop (And) so that it was possible to take out a lock plate of HAZET 2588-2.
  1. Turn slowly the tension device clockwise (overcoming resistance) so that between the tension lever and the case it was possible to insert easily a drill (2) with a diameter of 4.0 mm. Size and = 4.0 ± 1.0 mm.
  1. Holding a tension roller in this situation tighten a nut of a tension roller (1) moment 20nm + 45 °.
  1. Tighten bolts (arrows on an illustration) fastenings of a wheel of a camshaft the moment 25nm.
  1. Take out a lock finger HAZET 2588-3 and a stopper of a cranked shaft of HAZET 2588-1.

The cranked shaft is allowed to be rotated only in the direction of rotation of the engine.

  1. Turn a cranked shaft 2 turns farther clockwise so that it again stopped in position VMT of the first cylinder.
  1. Double-check the and size between the tension lever and the case of the tension device. The demanded value: and = 4.0 ± 1.0 mm.
  2. If the and size is not reached, tighten a tension roller in way described below.
  3. Holding a tension roller the HAZET 2587-1 tool, turn off a nut (1). After that on action of effort of the tension device release it so (arrow) to reach the and size. The demanded value and = 4.0 ± 1.0 mm.
  4. Holding a tension roller in this situation, tighten a nut (1) moment 20nm + 45 °.

Check of phases of gas distribution

 PERFORMANCE ORDER

  1. For monitoring procedure record once again a wheel of a gear belt a stopper of a cranked shaft of HAZET 2588-1. Thus keep in mind the following:
  • Tags on a wheel (2) and a stopper of a cranked shaft (1) have to be opposite to each other. Thus the pin of a stopper of a cranked shaft (shooter) has to enter an opening of a sealing flange.
  • The pin of a stopper of a cranked shaft at rotation has to enter an opening on a sealing flange (an arrow on an accompanying illustration).
  • If the cranked shaft passed through a tag of VMT of the first cylinder, turn off a shaft on 90 ° back so that it again at rotation in the set direction stopped in position VMT of the first cylinder.

Adjustment by rotation of a shaft back for the purpose of installation of a stopper is not allowed.

  1. Check, whether the nave by means of a lock level of HAZET 2588-3 is fixed.
  1. The interval between pads (1) on a rotor of the sensor of a camshaft has to lie against marking "4Z" (2) on a back cover of a gear belt.

If the nave is not fixed

 PERFORMANCE ORDER

  1. Turn off bolts of fastening (arrow) of a wheel of a camshaft.
  1. Put a cap key on the central bolt of a camshaft and turn a nave so that the lock level of HAZET 2588-3 could enter.
  1. Tighten in this situation bolts of fastening (arrow) of a wheel of a camshaft the moment 25nm.
  1. Take away a lock finger HAZET 2588-3 and a stopper of a cranked shaft of HAZET 2588-1.

The cranked shaft is allowed to be turned only in the direction of rotation of the engine, i.e. clockwise.

  1. Turn a cranked shaft on 2 turnovers of the direction of rotation, a t.a clockwise so that the cranked shaft again rose in position VMT of the first cylinder.
  2. Repeat control of phases of gas distribution.
  3. Put the fan with the viscous coupling in a casing.
  4. Install into place the generator, thus for simplification of installation of the generator of the plug of lock bolts beat out a little back, address to the Section Removal and installation of the generator.
  5. Fix the fan with the viscous coupling a new bolt the moment 45nm.
  6. Establish maple a belt, address to the Section Removal and installation of a belt of the drive of auxiliary units.
  7. Install into place the forward panel, address to the Section Installation of the Forward Panel in situation for maintenance.











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