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
+ 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
   Specifications
   Removal and check point installation
   Check of level of oil in a manual check point
   Adjustment of the drive of gear shifting
   Check of adjustment of the lever of gear shifting
+ 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 has to be lifted on necessary height. Besides, the garage elevator is necessary for carrying out the specified operation. The operations described below belong to 5-staged a manual check point of cars with the forward drive.

Removal

 PERFORMANCE ORDER

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

Observe indications of the Section Replacement of the Battery.

 
  1. Uncover the engine, address to the Section Removal and installation of the top cover of the engine / the lower protection of a motive compartment / stretcher.
  2. Turn out nuts of fastening of a turbocompressor.
  3. Turn out all connecting bolts of an engine/check point which are available from above.
  1. Install to a traverse and a zastropta the engine.

The pipeline of supply of fuel is under pressure! Before opening of hose connection cover it with a thick rag. Then remove pressure by a careful detachment of a hose.

  1. Lift and install the car on supports.
  2. Models with parking heating: Turn out bolts of fastening of an exhaust pipe of parking/additional heating to the lower cover of a motive compartment.
  3. Turn off bolts of fastening and remove the holder of the lower cover of a motive compartment (shooter).
  4. Remove the heat-shielding screen over the right power shaft.
  5. Turn off bolts of fastening and uncover left and right (arrows) of an exhaust pipe.
  1. Remove a forward cross-piece of the tunnel (1) (an arrow on an accompanying illustration).
  1. Remove a reception pipe (3) from the terminal plug (2), address to Part of System of release and decrease in toxicity of the fulfilled gases. Turbocompressor.
  2. Remove the heat-shielding screen (4) over system of release.
  1. Turn out the lower connecting bolts of an engine/check point (an arrow on an accompanying illustration).
  1. Disconnect both power shafts on flanges and tie them on a wire, address to the Section Removal and installation of a power shaft.

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

  1. Remove a starter, thus do not disconnect a cable from a starter. Fix a starter on a wire to a body.
  2. On HUNDRED check points it is fixed and supported by the V.A.G elevator. If the specified elevator available is not present, bring under a check point the garage elevator with broad wooden laying and slightly raise a check point.
  1. Turn out at first bolts (2) and then bolts (3) on a tunnel cross-piece. Turn out both nuts (4), remove a tunnel cross-piece.
  1. Carefully lower the elevator with an engine/check point so that it was visible to a check point. Remove the elevator.
  1. Turn out a bolt (And) fastenings of a bar to a check point and disconnect the switching hinge from an axis.
  1. Disconnect the pushing bar having unscrewed the screw with an internal hexagon (In) at a check point.
  1. Take out the socket (1) if it is available, from the holder (the shooter on an accompanying illustration). Disunite the socket and take aside a cable.
  1. Disunite the socket (And) the sensor of a tachometer and (In) a backing lamp at a check point at the left.
  1. Disconnect the sensor of number of turns of the engine if it is available, for a check point at the left (an arrow on an accompanying illustration) and take him aside.
  1. Turn out the lower connecting bolts of engine/KPPP, but not bolts (And) and (In).
  1. Bring the corresponding elevator under a check point and record a check point a justified plate.
  2. Turn out the remained connecting bolts of an engine/check point (And) and (In).
  3. Wring out a check point from the engine and slowly lower down.

Installation

When replacing of any details or bolts established on a check point keep in mind the following: The check point case is executed from a magnesian or aluminum alloy. According to it these or those established details, such as a cover, and bolts are applied. If KPPP details from aluminum are established on the case from a magnesian alloy, the last will be exposed to corrosion. It belongs also to bolts of fastening of flange connection of an engine/check point. They have a special covering for the check point case from a magnesian alloy. A check point sign from a magnesian alloy is the inscription of "Mg AL 9 Zn 1" from the lower party of a check point and around a stopper for filling with oil.

 PERFORMANCE ORDER

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

The conducted disk of coupling has to come easily on primary shaft of a check point. Clean surplus of greasing.

  1. Clear all carving openings in which the self-stopped bolts, by a tap from the sealant remains are rolled. Surely replace the self-stopped bolts and nuts with the new.
  2. Check wear of the bearing of switching off of coupling, if necessary, replace. If on the plastic bearing there are flutes more deeply than 0.5 mm, the bearing needs to be replaced.
  3. Grease an adjacent surface of a pusher at the lever of the bearing of switching off of coupling with copper greasing, for example, of "Z381 351 TE".
  4. Check, whether the aligning plugs for centering of connection of an engine/check point in the block of cylinders stand still, if necessary, insert.
  5. Watch the correct provision of an intermediate plate at the engine if that is available.
  6. Enter horizontally a check point into coupling. If at installation primary shaft of a check point does not enter the conducted disk, turn a hand a shaft for a flange.
  7. Install the working cylinder of the 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 25nm.
  8. Establish into place a starter, address to the Section Removal and installation of a starter.
  1. Screw the lower bolts (And) for fastening of the engine with a check point and (In) for fastening of a starter.
  1. Lower the engine/check point block.
  2. Tighten the top bolts of fastening of an engine/check point the determined moment.
  1. Fix a tunnel cross-piece to the check point (1) support.
  2. Fix a tunnel cross-piece 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 45nm.
  1. Establish into place draft of gear shifting. Fix it the moment 20nm.
  2. Establish the pushing bar and fix it the moment 40nm.
  1. Establish power shafts and a guard of shaft, address to the Section Removal and installation of a power shaft.
  2. Join all earlier disunited sockets.
  3. When laying electric connections watch that all collars removed or which are cut off at dismantle were established on the former places.
  4. Install the heat-shielding screen of an exhaust pipe. Establish a reception pipe and install system of release, address to the Section Removal and installation of system of release. Replacement of the central, additional muffler, trailer pipe.
  5. Check adjustment of the drive of gear shifting, address to the Section Adjustment of the Drive of Gear Shifting.
  6. Check oil level in a check point, address to the Section Check of Level of Oil in a manual check point.
  7. Attach the negative (-) a battery cable.

Observe indications of the Section Replacement of the Battery.

Moments of a tightening of threaded connections

Bolts of fastening of an engine/check point. L engines 1.6, 1.8, 1.9, 2.0


Position

Bolt

Tightening moment

L engines 1.6, 2.0

1, 3, 4

M12 x 75

65nm

2

M12 x 90

65nm

5, 11

M12 x 110

65nm

7-10

M10 x 45

45nm

11 M12 x 130 65nm

And

The aligning plugs

L engines 1.8, 1.9:

1, 3, 4 M12 x 67 65nm
2, 6 M12 x 90 65nm
5, 11 M12 x 110 65nm
7-11 M10 x 45 45nm

And

The aligning plugs


Bolts of fastening of an engine/check point. L engines 2.4, 3.0


Position

Bolt

Tightening moment

Engine of 2.4 l

1, 9, 10, 11

M10 x 45

45nm

2

M10 x 135

65nm

3

M12 x 130

65nm

4, 5, 6

M12 x 67

65nm

7 M12 x 90 65nm
8 M12 x 80 65nm
And The aligning plugs
Engine of 3.0 l    
1, 9, 10, 11 M10 x 60 45nm
2 M10 x 150 65nm
3 M12 x 130 65nm
4 M12 x 80 65nm
5, 6, 8 M12 x 90 65nm
7 M10 x 100 45nm
And The aligning plugs

Fastening bolts support engine/stabilizer

1 — the Stabilizer (2) to the engine 25nm support console
3 — an engine Support to the engine 25nm support console

Nuts (1) are surely replaced.











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