AUDI A4 1997 B5 / 1.G AFC Engine Cylinder Block Crankshaft And Flywheel Component Assembly Manual

13-6


Cylinder block, crankshaft and
flywheel, component layout Note:
Always replace gaskets and seals.
1 -
Main bearing cap bolts
Always replaceTightening torque: 60 Nm (44 ft lb) plus
1/2-turn (180 )
2 -
Main bearing cap
ID: "1" on side facing oil pumpAlways replace boltsChecking bearing clearance page 13
-21
3 -
Connecting rod bearing cap bolts
Always replaceTightening torque: 30 Nm (22 ft lb) plus
1/4-turn (90 ) Tighten to 20 Nm (15 ft lb) for measuring
radial clearance, but do NOT tighten further
4 -
Connecting rod bearing shells Never interchange used connecting rod
bearing shells
Pa
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ylinder block, crankshaft and fl
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Checking connecting rods and bearings
page 13
-31

Pa
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ylinder block, crankshaft and fl
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13-7


5 -
Piston rings
Checking page 13
-25
6 -
Piston
Checking page 13
-26
7 -
Crankshaft
Checking page 13
-21
Dimensions page 13
-24
8 -
Oil pump
Check drive gear on crankshaft when
installing Removing Repair Group 17
9 -
10 Nm (7 ft lb)
10 -
Thrust washers
Installed only at 4th crankshaft main
bearing Checking crankshaft axial clearance
page 13
-21

11 -
Bolt
Automatic trans. (drive plate)
Always replaceTightening torque: 60 Nm (44 ft lb) plus
1/4-turn (90 )
Pa
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ylinder block, crankshaft and fl
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ponent la
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Manual trans. (flywheel)
Always replaceTightening torque: 40 Nm (30 ft lb) plus
1/2-turn (180 )
Pa
ge 4 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
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13-8


12 -
Dual mass flywheel or drive plate
Removing and installing, installation
dimensions page 13
-17

Removing and installing pilot needle
bearing page 13
-16

Adjusting engine speed (RPM) sensor
bracket -G28- page 13
-20

13 -
Main bearing shell
Checking radial clearance page 13
-21
14 -
Seal
Replacing page 13
-14
15 -
10 Nm (7 ft lb)
16 -
25 Nm (18 ft lb)
Thread bolts in hand-tight before tightening
crankshaft main bearing caps
17 -
Cylinder block
Pa
ge 5 of 32 C
ylinder block, crankshaft and fl
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13-9

Ribbed belt, removing and installing


CAUTION!

Mark the direction of belt travel before
removing, using a crayon or marker.
Reinstalling a used belt in the opposite
direction could damage the belt.

Removing

- Remove engine and ribbed-belt guard.

- Loosen ribbed-belt tensioner using 17 mm
wrench and secure with locking drift 3204.

- Remove ribbed belt.

Installing

- Install ribbed belt over the crankshaft belt pulley
and guide pulley first, and then push it onto the
tensioning pulley.

- Remove locking drift 3204.

- Install engine and ribbed belt guard.

Routing of ribbed belt drive -D-
Pa
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ylinder block, crankshaft and fl
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D1 - Without air conditioner
D2 - With air conditioner
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ylinder block, crankshaft and fl
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13-10

Vibration damper, removing and
installing


Removing
Removing ribbed belt page 13
-9 .

Note:
The center bolt does not have to be loosened to
remove the vibration damper.

- Remove vibration damper.

Installing

- When installing, make sure that notch (arrow) in vibration damper is
aligned with locking lug on toothed belt sprocket.
Tightening torque: 25 Nm (15 ft lb)
Pa
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ylinder block, crankshaft and fl
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13-11

Toothed belt, removing and installing


Removing

CAUTION!

Mark the direction of belt travel before
removing, using a crayon or marker.
Reinstalling a used belt in the opposite
direction could damage the belt.

- Remove ribbed belt page 13
-9 .

- Unclip toothed belt guard on both sides.

- Crank engine by hand to Top Dead Center (TDC) position.
- Check camshaft position. Large holes in camshaft sprocket locking
plates must face toward each other. If not, turn crankshaft one more
revolution.
- Remove Crankshaft Position (CKP) sensor from left-hand side of
cylinder block.
The TDC hole in the crankshaft must be aligned with the hole for the
removed crankshaft position sensor (check by looking and feeling).

- Thread crankshaft holder 3242 into hole left by crankshaft position
sensor, and tighten slightly.
- Remove ribbed-belt tensioner.
Pa
ge 9 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
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13-12

- Remove left and right toothed-belt guards.

- Remove vibration damper page 13
-10
.

- Remove lower toothed-belt guard.

- Loosen toothed-belt tensioning pulley, and
remove belt.

Installing

Note:
The arms of the puller must engage on the rear hub of the sprocket. - Loosen right and left camshaft sprockets from tapered ends of
camshafts using puller (Kukko 20-10 or equivalent).
- Install toothed belt over both camshaft sprockets first, then over
remaining sprockets, and over tensioning roller last.

Note:
The camshaft sprockets must be loose enough on the tapered ends of the
shafts so that the camshafts can still be turned, but tight enough that the
sprockets do not tilt out of alignment. - Install camshaft holder 3243.
Pa
ge 10 of 32 C
ylinder block, crankshaft and fl
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ponent la
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