Repair and service Audi A8 in body D2 with 1994 for 1999 of release.
1. Car operation
2. Maintenance service
3. Petrol engines of 2,8 l
4. Petrol engines of 3,7 and 4,2 l
5. Diesel engines of 2,5 l
5.1. The general data
5.2. Recommendations about engine removal
5.3. A pulley of the pump of the amplifier of a steering
5.4. A poliklinovoj belt
5.5. A gear belt
5.6. A cranked shaft
5.7. A head of the block of cylinders
5.8. The klapannyj mechanism
6. Diesel engines of 3,3 l
7. Systems of ignition and injection of fuel of petrol engines
8. System of release of the fulfilled gases of cars with petrol engines
9. The power supply system of diesel engines
10. System of prestarting heating of diesel engines
11. System of release of the fulfilled gases of cars with diesel engines
12. Greasing system
13. Cooling system
14. Coupling
15. A transmission
16. Shaft of a drive of forward wheels
17. Features of a design of transmission of all-wheel drive cars
18. A suspension bracket
19. Wheels and tyres
20. A steering
21. Brake system
22. A body
23. Heating and air-conditioning system
24. An electric equipment
25. Electric schemes
 










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5.2. Recommendations about engine removal

Before the work beginning attentively familiarise with all section on engine removal.
If the engine remove for repair, it is necessary to choose a place for work, to provide space for service and storage of spare parts. To carry engine out repairs follows on a car repair shop or in garage with an equal horizontal floor with a pure firm covering.
Before removal clear of pollution and wash up the engine and a motor compartment. For engine removal use the load-lifting mechanism allowing safely to lift the power unit.
If you remove the engine for the first time, it is necessary to invite the skilled expert. Some works are carried out with the assistant.
All clips and collars which at engine removal will be damaged or cut, at engine assemblage it is necessary to replace with the new.
The engine acts in film forward without a transmission.
The merged cooling liquid is necessary for collecting and utilising.
Before a detachment of the storage battery find out, whether there is at you a code of inclusion of a radio receiver.

Removal
Switch off ignition and disconnect a wire of "weight" from the storage battery.

Fig. 3.3–24. An arrangement of screws of fastening of a casing of the engine



Turn away screws and remove an engine casing (fig. 3.3–24 see).

Fig. 3.3–1. An arrangement of protective casings (1–4) in a back part of a motor compartment



Remove protective casings 1–4 in a back part of a motor compartment (fig. 3.3–1).
Uncover a broad tank.

Fig. 3.3–25. An arrangement of forward air lines



Remove forward air lines (fig. 3.3–25 see).
Turn away a bolt of fastening of the fan of a radiator with вязкостной муфтой, keeping from проворачивания a fan axis other wrench.
Unscrew a casing of the fan of a radiator.
Remove the fan with вязкостной муфтой together with a casing.

Fig. 3.3–2. An arrangement of a clamp of a casing and a turn direction at removal of the fan of a radiator from an electric drive



For removal of the fan of a radiator from an electric drive disconnect from the fan an electric socket, take a casing clamp, turn a casing in an arrow direction (fig. 3.3–2) and remove the fan.

Fig. 3.3–27. An arrangement of screws of fastening of a casing semi wedge a belt



Turn out screws and remove a casing semi wedge a belt (fig. 3.3–27 see).

The prevention
Using a chalk, a marker or a paint, note a rotation direction semi wedge a belt. If at installation полиwedge the belt rotates in other party, it will lead to its destruction.


Fig. 3.3–28. An arrangement of a bolt of fastening of a tension roller semi wedge a belt of the compressor of the conditioner



Loosen the a bolt of fastening of a tension roller semi wedge a belt of the compressor of the conditioner also remove a belt from pulleys (fig. 3.3–28 see).

Fig. 3.3–29. Easing of a tension of the basic semi wedge a belt



Face key turn counter-clockwise the mechanism of a tension of the basic semi wedge a belt therefore the belt tension will be weakened, fix in this position the mechanism of a tension a pin (поз.1, fig. 3.3–29 see) and remove a belt.

Fig. 3.3–3. An arrangement of bolts of fastening гасителя fluctuations



Turn out eight bolts and remove гаситель fluctuations from a pulley of a cranked shaft (fig. 3.3–3).

Fig. 3.3–4. An arrangement of bolts of fastening of a thermofilter over турбокомпрессором



Turn out bolts (fig. 3.3–4) and remove a thermofilter over турбокомпрессором.


Fig. 3.3–5. An arrangement of bolts of fastening of a reception exhaust pipe to турбокомпрессору



Turn out bolts of fastening of a reception exhaust pipe to турбокомпрессору (fig. 3.3–5).

Fig. 3.3–34. An arrangement of screws of fastening of a heater of an exhaust pipe and a noise isolation of an additional heater



Turn out screws of fastening of a heater of an exhaust pipe and a noise isolation of an additional heater (fig. 3.3–34 see).

Fig. 3.3–35. An arrangement of clamps of fastening of the bottom mudguard of a motor compartment



Release clamps and remove the bottom mudguards of a motor compartment consisting of two sections (fig. 3.3–35 see).

Fig. 3.3–36. An arrangement of bolts of fastening of an arm of the bottom mudguard of a motor compartment



Turn out two bolts and remove an arm of the bottom mudguard of a motor compartment (fig. 3.3–36 see)
Loosen the collars also remove a forward exhaust pipe with catalytic neutralizer.
Establish under the engine the reception pallet for gathering of a cooling liquid.

Fig. 3.3–6. An arrangement of the crane plum of a cooling liquid (1) and a drainage bolt (2)



Merge cooling liquid, having turned on 90 ° the crane 1 (fig. 3.3–6) in the basis of a pipe and having turned out a drainage bolt 2.
Unscrew the compressor of the conditioner from an arm and, without disconnecting from it hoses, take him aside.
Turn out the jack of a twisting moment from the engine and a body.
Turn out an elastic support in the bottom right part of a frame.

Fig. 3.3–7. An arrangement of bolts of fastening of a starter: 1 – a nut; 2 – an electric socket



Disconnect from a starter an electric socket, then unscrew a nut 1 (fig. 3.3–7) and disconnect from a starter a positive wire.
Unscrew two bolts shown by arrows on fig. 3.3–7, and, being careful, remove a starter.

Fig. 3.3–8. An arrangement of a bolt of fastening of the hydrotransformer



Through the aperture which has opened after removal of a starter, unscrew three bolts of fastening of the hydrotransformer (fig. 3.3–8). For access to each subsequent bolt it is necessary to turn a cranked shaft of the engine in a direction of its working rotation on 1/3 turns.

The note
For проворачивания a cranked shaft it is necessary to use a bolt of fastening of a pulley of a cranked shaft.

Cars with a mechanical transmission
Unscrew and remove a casing from outside the right shaft of a drive.
In the right distributive block disconnect an electric socket and, having unscrewed a nut, remove a tip of a wire of a starter. Then unscrew a bolt of fastening of a clip of a wire and take a starter wire aside.
Disconnect an electric socket from the switch of a lantern of a backing.

All models
Unscrew and remove a casing from outside the left shaft of a drive.
Remove on the left side of a transmission a thermofilter.
Disconnect an electric socket from the speedometer gauge.

Fig. 3.3–9. An arrangement of an electric socket (1), the gauge of a speedometer, the gauge of frequency of rotation of the engine (2) and a bolt (3) fastenings of the pipeline of an automatic transmission


In the presence of the gauge 2 (fig. 3.3–9) frequencies of rotation of engine G28, unscrew it. The gauge 2  is located in a forward left part of a transmission.
Unscrew a bolt of 3 fastenings of the pipeline of an automatic transmission and move the pipeline aside.
Release from an arm and disconnect electric sockets of a plait of wires and the multipurpose switch.
Disconnect electric sockets on the left side of the engine.
Unscrew the bottom bolts of fastening of a transmission to the engine.

Fig. 3.3–10. An arrangement of bolts (arrow) of fastening of the engine to the bottom frame



Unscrew the bottom bolts shown by arrows on fig. 3.3–10, engine fastenings to the bottom frame.

Fig. 3.3–11. An arrangement of collars of fastening of hoses of system of cooling to heater unions on a partition of a motor compartment


Loosen the collars (fig. 3.3–11) also disconnect hoses of system the coolings going to a heater.
Remove a vacuum hose from the vacuum amplifier of brakes.
Loosen the collars also disconnect hoses of system of cooling from the engine.

Fig. 3.3–12. An arrangement of an electric socket of the gauge (1) in a hose (2) givings of air to an inlet collector



Disconnect an electric socket from the gauge of 1 air branch pipe (fig. 3.3–12).
Remove a hose of 2 givings of air to an inlet collector.

Fig. 3.3–21. An arrangement of bolts of fastening of a pulley semi wedge a belt of the pump of the amplifier of a steering and the special tool for deduction of a pulley from проворачивания



Unscrew bolts of fastening of a pulley semi wedge a belt of the pump of the amplifier of a steering, keeping a pulley from проворачивания the special tool (fig. 3.3–21 see).
Loosen the collars also remove an air branch pipe from the air filter.

Fig. 3.3–13. An arrangement of an electric socket (1) gauges of the fan of a radiator and collars of fastening of hoses of system of cooling from the gauge (2) and an additional heater (3)



Disconnect from the gauge 2 (fig. 3.3–13) the fan of system of cooling an electric socket 1 and a hose of system of cooling.
Loosen the collars also disconnect hoses of system of cooling from an additional heater 3.
Disconnect fuel hoses from the fuel filter.
Uncover the air filter.

Fig. 3.3–14. An arrangement of an electric socket of a flowmeter of air



Disconnect an electric socket from air flowmeter (fig. 3.3–14) and release wires from clamps.
Disconnect electric sockets from the electromagnetic valve and the valve рециркуляции the fulfilled gases (EGR).
Disconnect vacuum hoses from турбокомпрессора and mechanical system valves рециркуляции the fulfilled gases and move hoses aside.

Fig. 3.3–15. Races position of screws and a direction of removal of a casing of the block of management: 1 – a removal direction



Turn the left protective casing of the block of management in a direction of an arrow 1 (fig. 3.3–15) and turn out the back right screw.
Turn out the remained screws of fastening shown by arrows on fig. 3.3–15.
Remove a casing of the block of management.
In the management block disconnect electric sockets from blocks of engine management and a transmission. Release relay fastening for what, using a screw-driver with a thin edge, wring out lateral clamps.
Disconnect the remained sockets and remove a plait of wires from the top part of the engine.
Unscrew the top bolts of fastening of a transmission to the engine, having left one bolt on a place.
On a back part турбокомпрессора loosen the a bolt

Fig. 3.3–16. A bolt arrangement () rack fastenings () on a back part турбокомпрессора


And (fig. 3.3–16), turn a rack clockwise and again tighten a bolt.
Disconnect racks of support of a cowl from a cowl. Establish a cowl vertically and fix it in this position.
Suspend on таль load-lifting capture 2024 and fix its captures on the engine.
Unscrew bolts of fastening of a transmission to the engine.
Check up, that all electric wires, hoses, branch pipes and pipelines have been disconnected from the engine.

Cars with an automatic transmission

Fig. 3.3–17. Use of the big screw-driver for hydrotransformer pressing to the engine at engine removal



Before removal of the engine by the big screw-driver press the hydrotransformer to the engine (fig. 3.3–17).
Being careful, raise the engine, then take away it from a transmission and take upwards from a motor compartment.

Cars with an automatic transmission
Fix the hydrotransformer on the engine.

Installation
Installation is spent to sequences, return to removal, taking into account the following.
At engine installation it is necessary to replace on new self-locking nuts and bolts which tightened доворачиванием on a certain corner, and also sealing rings and linings.
Before installation be convinced that the rack In (fig. 3.3–16 see) on a back part турбокомпрессора is turned clockwise.
Before engine installation fix on each side a motor compartment electric wires and hoses that them has not clamped the engine.
At installation check up presence of the aligning plugs defining a relative positioning of the engine and a transmission.

Cars with a mechanical transmission
Clear Slots a power shaft and at a reuse of a disk of coupling remove from it corrosion traces. Grease Slots a drive shaft with a thin layer of greasing G 000 100.
Check up a condition of the bearing of deenergizing of coupling and if necessary replace it.
Using the mandrel, check up a centering of a disk of coupling.
Check up a condition of the needle bearing in an end face of a cranked shaft from outside a flywheel. If necessary replace the bearing.

Cars with an automatic transmission
For hydrotransformer fastening to a flywheel it is necessary to use bolts of an original design.

Fig. 3.3–18. Distance measurement between a basic surface for bolts of fastening of the hydrotransformer and a basic surface картера



Check up correctness of installation of the hydrotransformer. If the distance between a basic surface for bolts of fastening of the hydrotransformer and a surface картера makes 19 mm, means, the hydrotransformer is established correctly. At incorrectly established hydrotransformer this distance makes about 14 mm (fig. 3.3–18). The leading disk of the hydrotransformer and the pump of an automatic transmission In this case collapses.

Establish the engine into place and, shaking it here and there, provide a correct arrangement on support.
Establish the compressor of the conditioner and the pump of the amplifier of a steering.
Before ввинчиванием bolts of fastening of the compressor of the conditioner be convinced that aligning plugs of the compressor are on a place.
Establish полиwedge a belt.
Establish the fan of a radiator with вязкостной муфтой.
Establish the jack of a twisting moment and screw it on the engine and a body.
Fill in in cooling system cooling liquid. The reuse of a cooling liquid is not supposed, if the head of the block of cylinders acted in film or the block of cylinders was replaced.
Check up, that elements of system of release have been correctly established on suspension brackets and bodies did not concern at its rocking.
Check up correctness of connection of electric sockets.
Connect "a weight" wire to the storage battery.
Include a radio receiver and enter into it a code.
Lift glasses electric glass lifts upwards against the stop. Then press all switches стеклоподъемника once again, at least for 1 second, in position of closing for activation of the block of management glass lifts.
Establish time for hours.
Before the first start-up of the engine it is necessary to pump over fuel system, the fuel pump otherwise will be damaged.
Before engine start-up check up presence and oil level in the engine.


5.1. The general data

5.3. A pulley of the pump of the amplifier of a steering