AUDI A3 2000 8L / 1.G AEB ATW Engines Crankshaft Workshop Manual

13-46


Crankshaft, removing and
installing Note:
For engine disassembly and assembly, mount
engine to an assembly stand using VW540 holding
fixture.
1 -
Main bearing shells 1, 2, 4 and 5
Install shell without lubrication groove in
main bearing cap Install shell with lubrication groove in
cylinder block Do not interchange used main bearing
shells (mark accordingly)
2 -
Main bearing cap bolts Always replace65 Nm (48 ft lb) + additional 1/4 turn (90 )To measure radial play in crankshaft,
tighten to 65 Nm (48 ft lb) but not any
further
3 -
Main bearing caps Bearing cap 1: belt pulley sideRetaining tabs for cylinder block/bearing
cap must overlap
Pa
ge 1 of 8 Crankshaft, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.3

13-47


4 -
Main bearing shell 3
Install shell without lubrication groove in
main bearing cap Install shell with lubrication groove in
cylinder block Do not interchange used main bearing
shells (mark accordingly)
5 -
Thrust plates For bearing cap, bearing 3Check location point
6 -
Sensor wheel Always replace when bolts are removedFor engine speed (RPM) sensor -G28-Installation only possible in one position;
bore holes are offset Removing and installing Fig. 1
7 -
Sensor wheel screws
Always replaceAlways replace sensor wheel when bolts
are removed 10 Nm (7 ft lb) + additional 1/4 turn (90 )
Pa
ge 2 of 8 Crankshaft, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.3

13-48


8 -
Needle bearing
Removing and installing Page 13
-50
9 -
Crankshaft
Axial play when new: 0.07-0.23 mm (0.003-
0.009 in.) Wear limit: 0.30 mm (0.012 in.)
- Radial clearance is measured using
Plastigage New: 0.02-0.04 mm (0.0008-0.0016 in.)Wear limit: 0.15 mm (0.006 in.)Do not turn crankshaft when measuring
radial play Crankshaft dimensions Page 13
-52Pa
ge 3 of 8 Crankshaft, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.3

13-49


Note:
Tightening torque Fig. 1 Removing and installing sensor wheel
- Always replace sensor wheel -2- when screws -1- are removed.
After tightening a second time, the attachment point of the
countersunk screws of the sensor wheel are so deformed that the
screw heads sit against crankshaft (arrows) -3- and the sensor wheel
is loose underneath the screws. Installation of the sensor wheel is only possible in one position; bore
holes are offset.
Component

Tightening torque
Sensor wheel to crankshaft
10 Nm (7 ft lb) + 90
1) 2)

1) Replace bolts. 2) 90 are equivalent to 1/4 turn.
Pa
ge 4 of 8 Crankshaft, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.3

13-50

Crankshaft needle bearing, removing
and installing


Note:

A pilot needle bearing must be installed in the
crankshaft of engines for vehicles with manual
transmission. Install if necessary.
A pilot needle bearing must not be installed in
the crankshaft of engines for vehicles with
automatic transmission. Remove if necessary.

Special tools and equipment
21/1 Kukko puller and 22/1 Kukko support
or
10-202 puller
VW207C drift
or
3176 centering mandrel

Removing
Pa
ge 5 of 8 Crankshaft, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.3

- Pull out using puller -A-, e.g. 21/2 Kukko extractor and 22/1 Kukko
support or 10-202 puller.
Pa
ge 6 of 8 Crankshaft, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.3

13-51

Installing

- Drive in using VW207C drift and/or 3176 centering mandrel.
When needle bearing is installed, side with inscription must be visible.

Installation of needle bearing:
Dimension -a- = 1.5 mm (0.059 in.)
Pa
ge 7 of 8 Crankshaft, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.3

13-52
Crankshaft dimensions Reconditioning dimension
Crankshaft journal diameter - mm (in.)
Connecting rod journal diameter - mm (in.)

maximum size (from nominal) -0.017 (0.0007) -0.022 (0.0009)
Basic dimension (nominal) 54.00 (2.126) 47.80 (1.882)
minimum size (from nominal) -0.037 (0.0015) -0.042 (0.0017)
maximum size (from nominal) -0.017 (0.0007) -0.022 (0.0009)
1st undersize (nominal) 53.75 (2.116) 47.55 (1.872)
minimum size (from nominal) -0.037 (0.0015) -0.042 (0.0017)
maximum size (from nominal) -0.017 (0.0007) -0.022 (0.0009)
2nd undersize (nominal) 53.50 (2.106) 47.30 (1.862)
minimum size (from nominal) -0.037 (0.0015) -0.042 (0.0017)
maximum size (from nominal) -0.017 (0.0007) -0.022 (0.0009)
3rd undersize (nominal) 53.25 (2.096) 47.05 (1.852)
minimum size (from nominal) -0.037 (0.0015) -0.042 (0.0017)
Pa
ge 8 of 8 Crankshaft, removin
g and installin
g
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.13.3