3.4. Removal and engine / RKPP installation

Engine of 1.8 l

The engine together with RKPP is removed down. Removal of the engine/RKPP block requires the crane. Do not remove the engine/RKPP block at all by means of the garage elevator since it can become the reason of heavy damages of the engine.

As on the lower party of the car it is necessary to turn off several connections, four supports, and for a car raising the elevator are required. Before installation of the engine wings in a motive compartment have to be protected by covers.

Depending on year of release of the car and its equipment electric wires, and also vacuum hoses and hoses of the cooling system can have various laying. As here it is not possible to describe laying of all possible options, it is recommended to mark the respective lines before a rassoyedineniye.

Necessary special tool and auxiliary material:

- Crane
- A clip for spring collars, for example, HAZET 798-5
- Load-lifting suspension bracket, for example, AUDI 2024 A
- MoS2 lubricant, for example, AUDI G 000 100
- A dynamometer key on 5:50 N • m
- A dynamometer key on 40:200 N • m
- Cable connector

REMOVAL

ATTENTION

Cable connectors which act or cut at removal of the engine have to be established on the former places. For this purpose it is necessary to mark places of their installation. For undocking of connections it is necessary to press stoppers and to pull for the plug.

PERFORMANCE ORDER
1. Disconnect a negative cable (-) of the rechargeable battery at the switched-off ignition.
ATTENTION

Thereof information from electronic blocks of memory, such as, a radio receiver code is erased. Without code the radio receiver can be switched on only by the manufacturer or HUNDRED AUDIS. Therefore study instructions in the subsection Input of a Code of the Radio Receiver.

2. Remove the rechargeable battery, address the subsection Removal and installation of the rechargeable battery.
3. Turn off bolts of fastening and take out the holder of the rechargeable battery.
4. Remove the actuator, address the subsection Check, removal and installation of the traction relay of a starter.
5. Remove the case of the air filter, address the subsection Removal and installation of the case of the air filter.
6. Turn off bolts of fastening and remove the air duct to the air filter on a bumper.
7. Remove the lower cover of a motive compartment, address the subsection Removal and installation of the lower cover of a motive compartment.
8. Remove the right power shaft, address the subsection Removal and installation of power shafts.
9. Disconnect the left power shaft from a flange of RKPP and tie a wire to the stabilizer or the bottom.
10. Merge cooling liquid, address the subsection Replacement of Cooling Liquid.
11. Engine of 150 h.p.: Remove connecting pipes between a turbocompressor/radiator of the forced air, a turbocompressor / the air filter and a radiator of the forced air / the inlet pipeline. For this purpose remove collars from hoses.
12. Weaken a tension of a maple belt and remove it, address the subsections Removal and installation of a ridge maple belt and Removal and installation of a maple belt.
13. Turn off bolts of fastening and remove the pump of the hydraulic booster from the holder, tie him a wire to a body. Do not disconnect hoses.
ATTENTION

Do not press hoses. If the system at removal was opened, it is necessary to remove air from it, address the subsection Removal and installation of the pump of the power steering.

Cars with the conditioner:
ATTENTION

Do not open a contour of cooling of the conditioner. Hit of cooling liquid on skin can cause a frostbite.
Turn off collars of fastening of the cooling system of the conditioner. Do not twist, do not press and do not bend pipelines and hoses of the conditioner.

14. Turn off bolts of fastening of the compressor (A) and (In) and tie the compressor a wire to the cowl lock so that not to pull hoses.
15. Remove a reception pipe of the muffler and the catalytic converter, address the subsection Removal and installation of system of release.
16. Disconnect a gas drive cable, do not delete a stopper, address the subsection Adjustment of the Drive of Gas.
17. Uncover the engine at inlet the pipeline.
18. Rasstykuyte shtekerny connections of-1 coils of ignition and-3 injectors. Disconnect a negative cable-2-. On soprovoditelno illustration the engine of 150 h.p. is shown.
19. Disconnect the vacuum pipeline-4-on pressure regulator.
20. Disconnect at the engine and a turbocompressor (h.p. engines 150 and 180) the vacuum and soaking-up hoses. If necessary apply on hoses and connecting unions of marking to exclude a mistake at assembly.
21. Rasstykuyte all shtekerny connections from the engine and RKPP to a body.
ATTENTION

The fuel system is under pressure! Before opening of hose accessions cover them with a thick rag. After that carefully take off pressure. Use goggles. Danger of defeat by splashes!

22. Disconnect pipelines of giving-1-and return-2-at the fuel distributor for what squeeze release buttons on the coupling. Mark hoses a tape for simplification of the subsequent assembly.
23. Close fuel-supply lines a film and rubber rings to exclude hit in system of dirt.
24. Disconnect 2 hoses of cooling liquid to the heater heat exchanger at a forward wall of a motive compartment for what open collars.
25. Remove all hoses of cooling liquid from the engine to the top part and to a broad tank for what open collars and remove hoses.
26. Remove the fan with the holder, address the subsection Removal and installation of a radiator and the fan.
27. Cars with RKPP: Remove drives of switching and the cylinder of coupling.
ATTENTION

After removal of the working cylinder of the drive of coupling do not press a coupling pedal.

28. Cars with AT: Turn off bolts of fastening and remove the holder of the pressure head pipeline of the hydraulic booster at a box support. Remove a selector cable at the check point, address the subsection Adjustment of a Cable of the Selector of Switching of Automatic Transmission.
29. Turn off bolts of fastening of a pendular support below between a body and the block the engine/transmission.
30. Raise the car. It has to be at distance not less and = 60 mm from the earth.
31. Put on the earth wooden whetstone (shooter) the sizes of 40 x 30 cm and 15 cm thick for installation of the engine on it around the case pallet.
32. Connect the load-lifting AUDI-2024A device to a hook 3180 with eyes on the engine. Connect the vertical punched tires to openings of 1 and 5 cross tires. Implant from an engine flywheel a finger into the second opening of the tire, from a pulley in the third opening. Openings are considered from a hook.
ATTENTION

Apply lock pins on hooks and the fixing pins. For coordination with the unit center of gravity the punched tires have to be correctly exposed on length.

33. If the corresponding load-lifting device is unavailable, it is possible to apply a chain to raising of the unit.
34. Raise the block the engine/transmission the crane so that to unload engine support.
35. Turn off from above the right support of an engine/box.
36. Turn off bolts of fastening of a support of a box at the left
37. Check that all hoses and pipelines going from the engine and a box to the chassis were disconnected.
38. Pull the block an engine/box forward as far as it perhaps and slowly lower on wooden laying. Carry out operation carefully not to damage mechanisms.
ATTENTION

Fix the block that it did not overturn.

39. If necessary, disconnect a box from the engine, address the subsection Removal and the RKPP installation.
INSTALLATION
40. Check existence of a time and cracks in rubber support of the engine and hoses of cooling, oil and fuel. If it is necessary, replace.
41. Only, if the engine was disconnected from a box: Check coupling. Insert fastening bolts an engine/box and tighten their determined inhaling moment. At the same time be guided by instructions in the subsection Removal and the RKPP installation.
42. Install into place the block an engine/box and fix by hand by new bolts.
43. Fix the pendular lever by hand by new bolts.
44. Expose the block an engine/box strong rockings by his hands.
45. Fix support of an engine/box and the pendular lever according to the values of torques given in Specifications. At the same time at first tighten all bolts a dynamometer key and then tighten bolts a rigid key on a corner 90 ° (1/4 turns).
ATTENTION

Bolts at an inhaling receive residual lengthening. Therefore after each inhaling it is necessary to apply new bolts.
Before an inhaling measure diameter of a carving of a bolt since the inhaling moment depends on it.

46. If the conditioner compressor was removed, fix by its moment 45 N of m.
47. Fix the power steering pump, address the subsection Removal and installation of the pump of the power steering.
48. Establish a starter, address the subsection Removal and installation of a starter.
49. Put on maple a belt and pull it, address the subsections Removal and installation of a ridge maple belt and Removal and installation of a maple belt.
50. Fix the air duct to the air filter at the holder of the lock.
51. Install the case of the air filter, address the subsection Removal and installation of the case of the air filter.
52. Engine of 150 h.p.: Establish connecting pipes between a turbocompressor/radiator of the forced air, a turbocompressor / the air filter and a radiator of the forced air / the inlet pipeline. Fix hoses by collars.
53. Establish a reception pipe of the muffler / the catalytic converter with new consolidations, address the subsection Removal and installation of system of release.
54. Establish the left and right power shafts, address the subsection Removal and installation of power shafts.
55. Attach the drive of gas and adjust it, address the subsection Adjustment of the Drive of Gas.
56. Put on the giving and returnable fuel-supply lines a distributive pipe. Quick disconnect couplings have to be fixed distinctly.
57. Put on the heater hoses going from and to the heat exchanger at a forward wall of a motive compartment. Fix them by clips.
58. Install the radiator fan with the holder, address the subsection Removal and installation of a radiator and the fan.
59. Cars with RKPP: Install into place drives of switching and adjust them, address the subsection Gear Shifting Drive.
60. Establish a working hydraulic cylinder of the drive of coupling on RKPP, address the subsection Removal, installation and check of coupling.
61. Cars with AT: Fix the holder of the pressure head pipeline of the hydraulic booster on a box support. Establish draft of the selector on a box and adjust it, to the subsection Removal, installation and check of coupling.
62. Connect electric wires according to the markings put at removal and record them.
63. Fix electric wires on places of their former fastening. Record them collars.
64. Establish into place and fix the holder of the rechargeable battery.
65. Install the battery, without attaching still negative cable, address the subsection Removal and installation of the rechargeable battery.
66. Check that electric wires, vacuum hoses, hoses of cooling and fuel hoses were connected according to their markings.
67. Check oil level in the engine and the transmission, if necessary fill in oil.
68. Check availability of antifreeze in cooling liquid and if necessary add, address the subsections Replacement of Cooling Liquid and Check of Levels of Liquids, control of leaks.
69. Install an engine cover on the inlet pipeline.
70. Establish the lower cover of a motive compartment, address the subsection Removal and installation of the lower cover of a motive compartment.
71. Attach a cable of mass of the rechargeable battery.
ATTENTION

Make active high-rise automatic equipment of the power window, and also establish hours and enter a radio tape recorder code, address the subsection Input of a Code of the Radio Receiver.

72. Start and warm up the engine up to the working temperature. Check the level of oil and cooling liquid. Check tightness of all hose connections.
73. Check adjustment of headlights, address the subsection Adjustment of Light of Headlights.
ATTENTION

When undocking various electric connections in monitors malfunctions which after installation have to be removed register. As the electronic tester which joins the diagnostic socket of the car for this purpose is required. For this purpose it is necessary to address on HUNDRED.