engine AUDI A4 1996 B5 / 1.G AFC Engine Cylinder Block Crankshaft And Flywheel Component Assembly Manual

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
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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-
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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
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13-15

Flywheel/drive plate end (rear)

CAUTION!

Always replace the seal with the flange, if
available. Drain engine coolant before
removing flange ( Repair Group 19).
Replace only seal as described below if oil
seal with flange is not available.
- Remove clutch and flywheel, or drive plate, as
necessary.

Note:
Do not oil sealing lip or outer edge of seal before pressing in. - Pry out oil seal with extractor 10-221.
- Clean running and sealing surfaces.

- Using assembly aid supplied with new oil seal, slide seal onto
crankshaft.
Assembly aid is supplied with oil seal
- Press in oil seal as far as possible using seal installer 2003/3 and
flywheel or drive plate mounting screws.
Pa
ge 15 of 32 C
ylinder block, crankshaft and fl
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ponent la
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13-17

Dual mass flywheel or drive plate,
removing and installing


Flywheel

Note:
The needle roller bearing is in the flywheel and must be pressed in when
replacing the flywheel.
Tightening torque - Install crankshaft holder 3242 with crankshaft at Top Dead Center
(TDC) position.
- Mark relationship between flywheel and engine cylinder block (arrows).
- Remove flywheel.
Dual mass flywheel: 40 Nm (30 ft lb) plus 1/2-turn (180 )
Pa
ge 17 of 32 C
ylinder block, crankshaft and fl
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13-19


Note:
Before installing the engine, make sure that the engine-to-transmission
dowel sleeves are installed in the cylinder block flange. - Check clearance -a- between drive plate and cylinder block in three
places and calculate average value.
Dimension -a-:

Transmission 01V: 18.1-19.7 mm (0.713-0.776 in.)
- If necessary, install other shims to achieve correct clearance
dimension.

Tightening torque: 60 Nm (44 ft lb) plus 1/4-turn (90 )
Pa
ge 19 of 32 C
ylinder block, crankshaft and fl
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13-20

Engine speed (RPM) sensor mounting
bracket, adjusting


Note:
The crankshaft must be at TDC and locked in
position with crankshaft holder 3242 page 13
-
11
.

- Remove heat shield for RPM sensor, and then
remove RPM sensor.

- Loosen bracket.

- Insert adjustment tool 3308 in place of sensor.
Adjustment tool must engage in flywheel ring gear.
- Tighten bracket securely.
- Install RPM sensor.
Pa
ge 20 of 32 C
ylinder block, crankshaft and fl
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ponent la
yout
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