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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5.5. A gear belt

The note

Fig. 3.3–32. A gear belt: 1 – a pulley of a cranked shaft; 2 – the mechanism of a tension of a gear belt; 3 – a bolt, 10 Н·м; 4 – a bolt, 42 Н·м; 5 – the lever of the mechanism of a tension; 6 – a bolt, 42 Н·м; 7 – a washer; 8 – a tension roller; 9 – a bolt, 75 Н·м; 10 – a pulley of a camshaft of inlet valves; 11 – a gear belt; 12 – a bolt, 10 Н·м; 13 – the water pump; 14 – a bolt, 10 Н·м; 15 – the right back part of a casing; 16 – the central back part of a casing; 17 – the left back part of a casing; 18 – a lining; 19 – a pulley of a camshaft of final valves; 20 – a washer; 21 – a bolt, 75 Н·м; 22 – a directing roller; 23 – a casing of a gear belt; 24 – a bolt, 10 Н·м; 25 – a bolt, 45 Н·м; 26 – the plug; 27 – a bolt, 200 Н·м + to tighten on a corner 180 °


At installation it is necessary to use a new lining 18 (fig. 3.3–32) and a bolt 27.

Removal
Uncover маслоналивной mouths.

Fig. 3.3–33. A label on distributive to a shaft at installation of the piston of the first cylinder in ВМТ a compression step



For a bolt of fastening of a pulley turn a cranked shaft in a direction of working rotation before label occurrence «OT» (ВМТ) on distributive to a shaft in an aperture маслоналивной mouths (fig. 3.3–33).

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).

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



Release clamps and remove forward section of the bottom mudguard of a motor compartment (fig. 3.3–35).

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



Unscrew two bolts and remove an arm of the bottom mudguard of a motor compartment (fig. 3.3–36).

Fig. 3.3–37. An arrangement of the adjusting screw 3242 for fixing of a cranked shaft



Fix a cranked shaft in this position. For this purpose from the block of cylinders turn out заглушку and instead of it screw the adjusting screw 3242 (fig. 3.3–37).
Remove a casing located behind a broad tank.
Remove a vacuum hose from the vacuum pump.
Unscrew bolts of fastening of the vacuum pump and turn the pump counter-clockwise.
Loosen the collars also remove an air branch pipe from the air filter.
Disconnect electric sockets from the electromagnetic valve and the system valve рециркуляции the fulfilled gases (EGR).
Disconnect vacuum hoses from турбокомпрессора and the mechanical valve of system рециркуляции the fulfilled gases and move hoses aside.
Unscrew bolts and remove a pipe connecting турбокомпрессор with a cooler of air.

Fig. 3.3–38. An arrangement of the cover closing an end face of a camshaft, on the right head of the block of cylinders



Using a screw-driver edge as the lever, uncover, closing a camshaft end face on a head of the block of cylinders (fig. 3.3–38).
Establish instead of covers clamps of 3458 positions of camshafts.

Fig. 3.3–39. An arrangement of bolts (1) fastenings гасителя fluctuations and a nut (2) fastenings of a pulley of the fuel pump



Remove гаситель fluctuations from a pulley of the fuel pump (fig. 3.3–39). A nut of 2 fastenings of a pulley of the fuel pump not to unscrew, the moment of injection of the fuel pump otherwise will change.

The prevention
Before removal by a chalk, a marker or a paint note a direction of rotation of a gear belt. If at installation of the gear belt which was in the use it rotates in other party, it will lead to its destruction.

Loosen the the mechanism of a tension of a gear belt of the fuel pump also remove a belt.
Unscrew eight bolts and remove гаситель fluctuations from a pulley of a cranked shaft.

Fig. 3.3–40. An arrangement of bolts of fastening of a casing of a gear belt and an arm of the fan of a radiator: 1 – a bolt, 45 Н·м; 2 – bolts, 10 Н·м; 3 – bolts, 22 Н·м; 4 – a bolt, 10 Н·м



Unscrew a bolt of fastening of the bottom casing of a gear belt 4 (fig. 3.3–40).
Unscrew a bolt of a pulley of the fan of a radiator with вязкостной муфтой.
Unscrew bolts of fastening 1–3 arms of the fan of a radiator with вязкостной муфтой and single pulleys.
Unscrew bolts of fastening of a pulley of a gear belt from a pulley of the fuel pump.

Fig. 3.3–41. Use of the special adaptation 3036 (1) for fixing of a pulley of a camshaft from проворачивания



Using the special adaptation 3036 (fig. 3.3–41), fix a pulley of a camshaft from проворачивания and serially unscrew on one turn (but do not unscrew completely) bolts of fastening of a pulley of a camshaft.

Fig. 3.3–42. Easing of a tension of a gear belt



Face key on 8 mm turn a tension roller of a gear belt clockwise and fix its pin in diameter of 2 mm (fig. 3.3–42).

Fig. 3.3–43. Use of stripper Т40001  for removal of a pulley of a gear belt from a camshaft



Using stripper Т40001 (fig. 3.3–43), remove both pulleys of camshafts from landing cones of camshafts. Thus the stripper should rest against bolts of fastening of pulleys of camshafts. Pulleys of camshafts should rotate freely, but not dangle on their adjusting cones.
Unscrew a bolt and remove a pulley of a gear belt from the left head of the block of cylinders.
Remove a gear belt.

Installation
Check up, that position of camshafts has been fixed by clamps 3458, and the cranked shaft was in position ВМТ of the first cylinder in a compression step.
Pulleys of camshafts should be turned freely.
To establish a gear belt it is possible both on cold, and on the warm engine.
Between a pulley and cranked shaft there should not be a greasing.
First of all establish a gear belt on a pulley of a cranked shaft, then on a pulley of the right camshaft, a tension roller, a single pulley and a pulley of the water pump.
After that establish a gear belt on a pulley of the left camshaft, then a pulley on a camshaft and fix its bolt.
Face key on 8 mm turn a tension roller of a gear belt clockwise, take out fixing pin in diameter of 2 mm (fig. 3.3–42 see) and release a key.
Preliminary pull a gear belt, having turned a face key on 8 mm a tension roller counter-clockwise.
Using the special adaptation 3036 (fig. 3.3–41 see), fix a pulley of a camshaft from проворачивания and serially screw bolts of fastening of a pulley of a camshaft.

Fig. 3.3–44. Fixing by a pin 3359 pulleys of the fuel pump



Fix a pulley of the fuel pump a pin 3359 (fig. 3.3–44).
Establish a leading pulley of the fuel pump so that bolts settled down in the middle of the extended apertures of a pulley, and tighten bolts so that it was possible to turn a leading pulley of the fuel pump on a camshaft pulley.
Establish a gear belt of the fuel pump.
Adjust a tension of a gear belt of the fuel pump for what шестигранным a key turn the tension mechanism counter-clockwise before combination of labels, and the second key tighten a nut.
Remove clamps of 3458 camshafts.
Remove a pin 3359 fixing a pulley of the fuel pump.
Turn out the adjusting screw 3242 fixing a cranked shaft.
Remove the adjusting screw 3242 and clamps 3458, turn a cranked shaft on two complete revolutions, establish it in position ВМТ of the first cylinder in a step of compression and check up correctness of installation cranked and camshafts. For check of position of a cranked shaft unscrew from the block of cylinders заглушку and instead of it screw the adjusting screw 3242 (fig. 3.3–37 see). For check of position of camshafts establish the clamps 3458 fixing position of camshafts. If the adjusting screw 3242 and clamps 3458 were established, means, cranked and distributive shaft are established correctly.

Notes

Fig. 3.3–46. The oil pallet, forward and back covers of the engine: 1 – bolt M6, 10 Н·м; 2 – bolt M8, 30 Н·м; 3 – a sealing ring of a cranked shaft; 4 – a sealing ring of round section; 5 – натяжитель chains; 6 – a bolt, 10 Н·м; 7 – a directing pipe of the index (probeа) engine oil level; 8 – a sealing ring of round section; 9 – the top section of the oil pallet; 10 – a bolt, 45 Н·м; 11 – a casing; 12 – a bolt, 22 Н·м; 13 – bolt M6 to the block of cylinders, 13 Н·м; M6 to a cover, 10 Н·м; 14 – a bolt, 45 Н·м; 15 – bolt M6 to the block of cylinders, 13 Н·м; M6 to a cover, 10 Н·м; 16 – a two-mass flywheel; 17 – a bolt of fastening of a flywheel; 18 – the needle bearing; 19 – a lining; 20 – an adjusting pin; 21 – a bolt, 10 Н·м; 22 – a back cover with a sealing ring; 23 – a lining; 24 – the block of cylinders; 25 – a lining; 26 – a forward cover


1. At installation it is necessary to use new sealing rings 4, 8 (fig. 3.3–46) and linings 19, 23, 25.
2. The moment of an inhaling of a bolt of 17 fastenings of a flywheel makes 60 Н·м + to tighten on a corner 180 °, bolts of fastening of a frictional overlay for cars with an automatic transmission – 60 Н·м + to tighten on a corner 90 °. At installation it is necessary to use new bolts 17.
3. The needle bearing 18 is established only on cars with a mechanical transmission and запрессовывается in an end face of a cranked shaft.
4. The lining 19 at installation does not demand application of additional condensing means.
5. At installation of a sealing ring in a back cover 22 it is necessary to grease with a thin butter layer its working edge.

Establish гаситель fluctuations on a pulley of the fuel pump and fix its bolts.

Fig. 3.3–45. A label arrangement on гасителе fluctuations



Establish гаситель fluctuations on a pulley of a cranked shaft, be thus convinced that the label (fig. 3.3–45) was combined with a label on a pulley of a gear belt, and tighten fastening bolts гасителя fluctuations by the moment 22 Н·м.
On the left head of the block of cylinders establish the vacuum pump.
The further installation is spent to sequences, return to removal.


5.4. A poliklinovoj belt

5.6. A cranked shaft