AUDI A6 1995 C5 / 2.G AHA ATQ Engines Cylinder Block Crankshaft And Flywheel Component User Guide

13-12

Toothed belt, removing and installing


Removing

- Remove engine cover.

Ribbed belt, removing and installing page 13
-8 . - Remove noise insulation panel (arrows).
Lock carrier in service position page 13
-1
- Unclip toothed belt guard on both sides and remove.
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13-13


- Turn crankshaft at central bolt of toothed belt gear in direction of
engine rotation to cyl. 1 TDC. Timing marks -A- and -B- must be
aligned.

WARNING!
DO NOT turn crankshaft while checking for TDC mark. Personal
injury may result. - Check position of camshafts. Large holes (arrow) of securing plates on
camshaft sprockets must face toward inside and align.
If not, turn crankshaft one revolution further.
- Remove sealing plug from left-side of cylinder block.
- Top Dead Center (TDC) mark on crankshaft must be visible or be felt
behind bore of removed sealing plug.
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13-14


CAUTION!
Before removing ribbed belt, note direction of rotation with chalk or
felt-tip marker. Reversing the direction of rotation of a used belt can
destroy the belt. When installing the ribbed belt, make sure it is
seated correctly on the pulley.
Notes: - Install 3242 crankshaft holder into sealing plug opening.
- Remove tensioner for ribbed belt.
- Remove center and right toothed belt guards.
The toothed belt tensioner is oil dampened. Compress it by slowly
applying constant pressure. Use spring clamp from 2024A.

- Using 8 mm hex wrench, turn toothed belt tensioning roller -1- counter-
clockwise, opposite direction shown (arrow), until tensioning lever -2-
compresses tensioner -3- so that spring clamp (2 mm dia.) can be
inserted into bore and lifter.
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13-15

- Insert pin and release tension.

- Remove vibration damper page 13
-11
.

Installing - Remove idler wheel for ribbed belt (arrows).
- Remove toothed belt.

- Install 3391 camshaft locator bar onto camshaft locking plates.
- Loosen both bolts for camshafts and back out bolts approx. 5 turns.
- Remove 3391 camshaft locator bar.
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13-16


Note:
The camshaft sprockets should be loose enough on the cone to be
turned, but not so loose as to be tipped. - Remove both camshaft sprockets using T40001 special tool.
- Reinstall both camshaft sprockets together with locking plates and
hand-tighten.

- Install toothed belt on all sprockets as shown in illustration.
- Install 3391 camshaft locator bar.
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13-17


1) Always replace the center bolt. 2) Two turns of 90 are permissible. - Using 8 mm hex wrench, turn toothed belt tensioner roller -1- counter-
clockwise, opposite direction shown (arrow) until tensioning lever -2-
compresses tensioner -3- so that spring clamp can be removed and
then remove clamp.
- Before starting engine, pre-load timing tensioning roller as follows:
- Using a torque wrench with 8 mm hex bit, apply tension to toothed
belt clockwise in direction shown (arrow) until a torque of 15 Nm is
attained. This ensures tensioner has expanded completely and is
properly engaging toothed belt. Component
Tightening torque
Toothed belt sprocket to camshaft 55 (41 ft lb)
Idler wheel 45 (33 ft lb)
Toothed belt tensioning roller 20 (15 ft lb)
Belt pulley to crankshaft 20 (15 ft lb)
Toothed belt tensioner 10 (7 ft lb)
Center bolt 1) to crankshaft
200 (148 ft lb) + 180 2)
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13-18

Crankshaft seal, replacing


Toothed belt side

Lock carrier in service position page 13
-1
Ribbed belt, removing and installing page 13
-
8 .
Toothed belt, removing and installing page 13
-
12
.

- Remove sealing plug from left-side of cylinder
block.

- Turn crankshaft to TDC for cylinder 3. The TDC
mark on crankshaft must be visible or felt behind
bore for sealing plug.

- Install 3242 crankshaft holder in bore to secure crankshaft.
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13-19

- Remove crankshaft/toothed belt gear.

- Unscrew inner part of 3203 seal puller two turns
(approx. 3 mm) and secure using knurled bolt.

Installing - Grease threaded head of 2085 seal puller, position and with forced
pressure screw into oil seal as far as possible.
- Loosen knurled bolt and turn inner part against crankshaft until oil seal
is removed.
- Place 3202/1 guide sleeve on crankshaft pin.
- Slide dry oil seal over guide sleeve.

The rest of the installation follows is the reverse of removal. - Press in oil seal to stop using 3265 seal installer.
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13-20

Dual-mass flywheel

Notes:

Only replace oil seal with sealing flange.
Drain coolant before removing sealing flange
page 19
-11
.
If sealing flange is not available, proceed as
follows:

- Remove clutch and dual-mass flywheel or
driveplate.

Notes: - Pry out seal using 10-221 extractor.
- Clean running and sealing surfaces.
- Push seal onto crankshaft using assembly aid.
Do not lubricate sealing lip or outer edge of seal before pressing in.The assembly aid is supplied with the seal.

- Press in seal up to stop using 2003/3 seal installer and bolts for dual-
mass flywheel or driveplate.
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13-21

Dual-mass flywheel pilot needle bearing,
removing and installing


- Remove pilot needle bearing using puller -A- (e.g. KUKKO 21/2 and
KUKKO 22/1).
- Install bearing using 3264 bearing driver.
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ge 20 of 33 C
ylinder block, crankshaft and fl
ywheel, servicin
g
11/21/2002 htt
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yp
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