1. Disconnect a negative cable (–) of the rechargeable battery at the switched-off ignition.
ATTENTION Thereof information from electronic blocks of memory as, for example, a radio receiver code is erased. Without code the radio receiver can be switched on only by the manufacturer or HUNDRED AUDIS. Therefore get acquainted with materials of the subsection Check and replacement of brushes of the generator and regulator of tension.
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| 2. Remove a fan casing. |
| 3. Rasstykuyte socket of the sensor of a tachometer –1–, and also switch of back foggy lamps –2–. |
| 4. Turn off bolts of fastening and disconnect a damper and a cable of the drive of switching of RKPP (V). |
| 5. Disconnect a cable of the drive of the choice of transfers from the directing lever (C) for what raise a pad in the direction of an arrow. |
| 6. Disconnect a hose of the working cylinder at a cable support. Turn off bolts of fastening and disconnect a cable support on RKPP (are specified by shooters) and take aside. |
7. Turn off 2 bolts of fastening and disconnect the working cylinder from RKPP and fix with the attached hydraulic pipeline on one side bodies.
ATTENTION Do not disconnect the hydraulic pipeline, otherwise after installation of a hydraulic system it is necessary to remove from it air. At the removed cylinder do not press a coupling pedal.
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| 8. Disconnect a weight wire from the top bolt –1 RKPP/engine connections. Turn out a bolt –1–. |
| 9. Disconnect the holder of a cable-3-above at a starter (the shooter on an illustration) and take aside. |
| 10. Turn off a bolt –2– above at a starter. |
| 11. Turn out all bolts of fastening available from above between the engine and RKPP. |
| 12. You will hang out the engine. For this purpose install adaptation, for example, to AUDI 10-222A in combination with support 10-222A/1. |
| 13. Slightly raise the power unit by means of screws. |
14. If the specified adaptation is unavailable, put over a motive compartment a pipe and sideways to its oboprita on wooden whetstones. Do not put a pipe on wings. Hook on cables for engine eyes and connect to the screw. Pull a cable.
ATTENTION At rise and installation of the car on supports there is a danger! Therefore previously get acquainted with Poddomkrachivaniye's subsection of the car.
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| 15. Lift and install the car on supports. Remove the lower cover of a motive compartment, at the same time address the subsection Removal and installation of the lower cover of a motive compartment. |
| 16. Remove a starter. |
| 17. Turn off bolts of fastening and remove the holder of a wire of the drive of the hydraulic booster at RKPP case. |
| 18. Remove if is available, a protective cover of the right flange of a power shaft (And) |
| 19. Turn off a fastening bolt (the top arrow) of a small cover behind the right power shaft and uncover. |
| 20. Turn off bolts of fastening of power shafts and disconnect, at the same time address the subsection Removal and installation of power shafts. |
21. Suspend on a wire as it is possible above power shafts for what turn a steering wheel to the left against the stop.
ATTENTION
Do not damage at the same time a paint and varnish covering.
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| 22. Separate system of release between the catalytic converter and the central muffler, at the same time address the subsection Replacement of the Central/additional Muffler. |
| 23. Turn off bolts of fastening and disconnect a pendular support between a body and a side of engine/RKPP (the shooter on an illustration). |
| 24. Turn off bolts of fastening and disconnect a RKPP support bar at the left (an arrow A on an illustration), then disconnect the RKPP support (an arrow B on an illustration). |
| 25. Turn off bolts of fastening of the RKPP (A) support on a box and disconnect. To take out fastening bolts (are specified by shooters), lower the block dvigatel-RKPP by means of spindles so that bolts were available from the left wheel arch. |
ATTENTION
When lowering the unit you watch to damaging power steering pipelines.
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| 26. Fix the special tool (C) a bolt (V) at fastening of a pendular support from below. Insert the device for an extraction (A) and fix by bolts (are specified by shooters). Wring out the block dvigatel-RKPP forward. |
ATTENTION If the special tool is unavailable, the block dvigatel-RKPP can be shifted by an onboard jack forward. At the same time you watch to damaging power steering pipelines.
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| 27. Slightly raise RKPP the elevator, for example, of AUDI 3282. Previously arms of the RKPP support are exposed on a justified plate 3282/8. If the RKPP elevator is unavailable, raise RKPP a garage jack. |
ATTENTION Lay wooden laying between RKPP and a jack.
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| 28. Turn out the lower bolts of fastening between the engine and RKPP. |
29. Wring out RKPP from the directing plugs and carefully put forward.
ATTENTION At renting of RKPP you watch to damaging the pipeline of the hydraulic booster.
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INSTALLATION
ATTENTION If RKPP is replaced, rearrange the speedometer sensor, the lever of inclusion of transfers and the lever of switching from old RKPP to new.
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| 30. Before installation of coupling check it, at the same time address the subsection Removal, installation and check of coupling. |
31. Clear and slightly grease main shaft RKPP with MoS2 or AUDI-G 000 100 lubricant.
ATTENTION The clutch plate has to move easily on a shaft.
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| 32. Check whether the directing plugs for centering of the engine/RKPP block are installed in the block of cylinders. If necessary insert. |
| 33. Wring out the lever of switching off of coupling before the RKPP installation to a case of RKPP and record by means of an assembly bolt or a bolt of M8 x 35. After installation turn out a bolt. |
| 34. Raise RKPP and enter its coupling. If at the same time main shaft RKPP does not enter a clutch plate, turn hands a main shaft behind for a flange. At installation you monitor the correct provision of an intermediate plate. |
| 35. Turn and take out the special tool or a jack. |
| 36. Screw bolts of fastening of RKPP and a starter. For this purpose establish a starter. |
| 37. Screw bolts of fastening of the engine/RKPP block as far as possible deeply. |
| 38. Again turn out a bolt of M8 x 35 for fixing of the lever of switching off of coupling on a coupling casing. The opening is closed by a bolt of fastening of a support of draft of the drive. |
| 39. Fix by hand the left holder at RKPP and establish in the assembly provision of engine/RKPP by means of the crane. |
| 40. Tighten by hand the engine/RKPP support new bolts (In). |
| 41. Tighten by hand a pendular support new bolts. |
| 42. Remove the lifting device for the engine and RKPP. |
| 43. Level the engine/RKPP block, having strongly shaken it in different directions. |
44. Tighten the engine/RKPP block and a pendular support according to the values given in Specifications. At the same time tighten bolts at first a dynamometer key and then tighten a rigid key on a corner 90 ° (1/4 turns).
ATTENTION Bolts at an inhaling receive residual deformation. Therefore after each otvorachivaniye new bolts are applied.
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| 45. Establish power shafts, at the same time address the subsection Removal and installation of power shafts. |
| 46. Establish big and small covers of power shafts. |
| 47. Establish the left bolts of fastening of the holder of the engine and fix by the moment 50 N of m (on an illustration - an arrangement and the moments of tightening of bolts of fastening of the transmission). |
| 48. Establish a starter. |
| 49. Fix by bolts a cable support the moment of 25 N of m to RKPP. |
| 50. Fix a switching cable by the moment of 25 N of m to the gear shifting lever. |
| 51. Connect a choice drive cable to the switching lever. |
| 52. Fix a counterbalance on the gear shifting lever. Tighten fastening bolts at first a dynamometer key the moment of 20 N of m and then tighten a rigid key on a corner 90 ° (1/4 turns). |
| 53. Adjust the gear shifting drive, address the subsection Adjustment of the Drive of Switching. |
| 54. Fix the socket at RKPP, at the same time address the subsection "Removal". |
| 55. Join the socket at a starter. |
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56. Grease the end of a rod of the working cylinder of a hydraulic actuator with MoS2 lubricant. Insert into place the working cylinder and fix by its moment 20 N of m |
57. Several times press a pedal of coupling and check work.
ATTENTION If the hydraulic actuator opened, remove air from system.
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| 58. Establish a reception pipe / the catalytic converter with new sealing laying, at the same time address the subsection Removal and installation of system of release. |
| 59. Fix the holder of the pipeline of the power steering on RKPP case, at the same time address the subsection Removal and installation of the pump of the power steering. |
| 60. Check oil level in RKPP, at the same time address the subsection Check of Level of the RKPP Gearbox Oil. |
| 61. Establish the lower cover of a motive compartment, at the same time address the subsection Removal and installation of the lower cover of a motive compartment. |
| 62. Install the case of the air filter, at the same time address the subsection Removal and installation of the case of the air filter. |
63. Attach a negative cable (–) to the rechargeable battery.
ATTENTION Make active automatic equipment of safety of power windows, enter a radio receiver code, establish hours, at the same time address the subsection Input of a Code of the Radio Receiver.
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Especially for engines of 1.6 l
ATTENTION
The description of works and remarks concerning all RKPP are provided in subsection for engines 1.8 l. In the real subsection only the differences relating only to the engine of 1.6 l are described. These differences concern, first of all, the drive of switching which for the engine of 1.6 l happens through drafts, and at other engines through cables.
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| 64. You will hang out the engine by means of the crane, having hooked on the engine for eyes on a head of cylinders. |
| 65. Disconnect by means of the screw-driver forward draft –1– from the lever-2-. Remove a lock washer –3–, remove the console-4-. |
| 66. Disconnect the console-4 turn on 90 ° (1/4 turns) from draft with a damper –5– to the right. Reject draft with a damper up and remove from a bearing-6-support. |
| 67. Disconnect by means of the screw-driver long connecting drafts from the lever of the choice of transfers (are specified by shooters). Turn off a bolt and disconnect the forward lever of switching –1– at RKPP. |
| 68. Turn out bolts –2– and remove the console of switching –3– with connecting drafts and the lever of switching |
| 69. Disconnect a hose of the working cylinder at a support. Turn off 2 bolts of fastening and disconnect the working cylinder (are specified by shooters) at RKPP and fix with the attached hose to a body a wire. |
ATTENTION Do not disconnect the hydraulic pipeline, otherwise it is necessary to delete air from coupling after its installation. After removal of the working cylinder it is impossible to press a coupling pedal.
After the RKPP installation it is necessary to make adjustment of the drive of switching, at the same time address the subsection Dismantling of a Shaft of the Drive.
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