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

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
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pair&id=AUDI.B5.GE05.13.2

13-35

Needle bearing in dual-mass flywheel,
removing and installing


- Pull out with puller, such as KUKKO 21/2 and KUKKO 22-1.
- Drive in with drift 3264.
Pa
ge 22 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

13-36

Pistons and piston rings, installing


Pistons

Position: arrow on piston crown must always face in direction of travel.
Note:
Do not use a center-punch or similar, as pistons have a special coating.
Checking piston diameter - Mark cylinder number on piston crown with waterproof felt pen.

-
Measure pistons approx. 10 mm from bottom of skirt, at 90 to piston
pin axis.
Difference between actual and nominal diameter: not more than
0.04 mm.
Pa
ge 23 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

13-37


Ring-to-groove clearance Clearance when new
Wear limit
0.02 ... 0.08 mm 0.10 mm

Checking piston ring gap
- Push ring in squarely to a position approx. 15 mm from bottom end of
cylinder. Piston ring
Gap when new
Wear limit
1 0.35 ... 0.50 mm 1.0 mm
2 0.50 ... 0.70 mm 1.4 mm
3 0.25 ... 0.50 mm 0.8 mm
Pa
ge 24 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

13-38

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

13-39

Connecting rods and connecting rod
bearings, installing


Note:

Only replace complete sets of connecting
rods
Do not interchange connecting rod bearings.

Checking radial clearance - Before removing, mark positions of connecting rod bearing caps with a
felt pen or similar.
- Remove connecting rod bearing cap. Clean bearing cap and bearing
journal.
- Place a length of Plastigage corresponding to width of bearing on
bearing journal or bearing shell.
- Install connecting rod bearing cap and tighten to 20 Nm. Do not rotate
crankshaft.
- Remove connecting rod bearing cap again.
- Compare width of Plastigage with calibrated scale.Clearance when new
Wear limit
0.015 ... 0.062 mm 0.12 mm - Install new connecting rod bearing bolts.
Pa
ge 26 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