engine AUDI A4 1999 B5 / 1.G APB Engine Cylinder Block Crankshaft And Flywheel Assembly Manual

13-24

B - Flywheel end

Note:
Replace oil seal together with sealing flange.

Vehicles with manual transmission

- Drain off coolant Page 19
-19
.

- Remove transmission.

Repair Manual, 6 Spd. Manual Transmission
01E, Repair Group 34


- Remove clutch.

- With crankshaft at TDC, screw in clamping bolt 3242.
- Mark position of flywheel relative to engine -arrows-.
- Remove dual-mass flywheel.
- Remove sealing flange.
Pa
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ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
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pair&id=AUDI.B5.GE05.13.2

13-26

Vehicles with automatic transmission

- Remove transmission.

Repair Manual, 5 Spd. Automatic
Transmission 01V, Repair Group 37


- Drain off coolant Page 19
-19
.

Note:
Turn over the engine at the central bolt on the crankshaft.
CAUTION!
Injury risk - do not turn engine while feeling for TDC drilling. - Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.
- Check position of camshafts: larger holes in securing plates on
camshaft sprockets must align opposite one another on inside. If this is
not the case, turn crankshaft one revolution further.
- Remove sealing plug from cylinder block, left.
- The TDC drilling in crankshaft must be visible (or able to be felt) in line
with sealing plug hole.
Pa
ge 13 of 26 C
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ywheel, disassembl
y and assembl
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13-27


Installing - Screw clamping bolt 3242 for crankshaft into sealing plug hole and
tighten.
- Mark positions of holes in drive plate, shim -1- and washer -2- in
relation to crankshaft.
- Mark positions of shim -1- in front of drive plate and washer -2- behind
drive plate.

Note: - Install drive plate with washer -2- and shim -1- (3.0 mm or 4.0 mm).
Short engines and exchange engines are supplied without bush in
crankshaft. On vehicles with automatic transmission, always knock in
new bush before installing drive plate. Always replace drive plate securing bolts.
Pa
ge 14 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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13-28

Tightening torques

Drive plate to crankshaft
60 Nm + 90

Note:
Always replace securing bolts for drive plate.

Note:
Before installing the transmission, check that the dowel sleeves for
locating engine/transmission are fitted in the engine flange.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
- Measure distance -a- at three points and calculate average value.

Distance -a- = approx. 29.9 mm.
- Install a different shim if necessary.
- Install transmission.
Pa
ge 15 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
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pair&id=AUDI.B5.GE05.13.2

13-29

Dual-mass flywheel / drive plate,
installation dimensions, removing and
installing


A - Flywheel

Removing

- Remove transmission.

Repair Manual, 6 Spd. Manual Transmission
01V, Repair Group 34

- Remove clutch.

- With crankshaft at TDC, screw in clamping bolt 3242.
- Mark position of flywheel relative to engine -arrows-.
- Remove bolts (bolts must be replaced).
Pa
ge 16 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.13.2

13-31

Tightening torques

Dual-mass flywheel to
crankshaft 60 Nm + 180
Clutch to dual-mass flywheel 20 Nm

B - Drive plate

Removing

- Remove transmission.

Repair Manual, 5 Spd. Automatic
Transmission 01V, Repair Group 37


Note:
Turn over the engine at the central bolt on the crankshaft. - Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.
- Check position of camshafts: larger holes in securing plates on
camshaft sprockets must align opposite one another on inside. If this is
not the case, turn crankshaft one revolution further.
- Remove sealing plug from cylinder block, left.
Pa
ge 18 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.13.2

13-32

- TDC drilling in crankshaft must be visible (or
able to be felt) in line with sealing plug hole.

CAUTION!

Injury risk - do not turn engine while feeling
for TDC drilling.

- Screw clamping bolt 3242 for crankshaft into sealing plug hole and
tighten.
- Mark positions of holes in drive plate, shim -1- and washer -2- in
relation to crankshaft.
- Mark positions of shim -1- in front of drive plate and washer -2- behind
drive plate.
Pa
ge 19 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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e=re
pair&id=AUDI.B5.GE05.13.2

13-33

Installing

Note: - Install drive plate with washer -2- and shim -1- (3.0 mm or 4.0 mm).
Short engines and exchange engines are supplied without bush in
crankshaft. On vehicles with automatic transmission, always knock in
new bush before installing drive plate. Always replace drive plate securing bolts.
Tightening torques

Drive plate to crankshaft
60 Nm + 90
Pa
ge 20 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
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pair&id=AUDI.B5.GE05.13.2

13-34


Note:
Before installing the transmission, check that the dowel sleeves for
locating engine/transmission are fitted in the engine flange.
Repair Manual, 5 Spd. Automatic Transmission 01V, Repair Group 37
- Measure distance -a- at three points and calculate average value.

Distance -a- = approx. 12.3 mm.
- Install a different shim if necessary.
- Install transmission.
Pa
ge 21 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
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pair&id=AUDI.B5.GE05.13.2

13-38

Cylinder bores, checking


Piston and cylinder dimensions
Note:
Replacement pistons are only available with basic dimension. - Measure bores at three points in both directions: across engine -A- and
in line with crankshaft -B-.
Use internal dial gauge 50 to 100 mm.

Difference between actual and nominal diameter: not more than
0.08 mm.
Honing dimension
Piston dia.
Cyl. bore dia.
Basic dimension 80.95 mm 81.01 mm
Pa
ge 25 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE05.13.2