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

13-14


Cylinder block, crankshaft and
flywheel, disassembly and
assembly Note:
Replace all gaskets and seals.
1 -
Thrust washers
Measuring axial clearance of crankshaft
Page 13
-21

Thrust washer only fitted on 4th crankshaft
bearing
2 -
Special bolt (double hex) ReplaceDual-mass flywheel: 60 Nm + 180 (1/2
turn)
Pa
ge 1 of 26 C
ylinder block, crankshaft and fl
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13-15


3 -
Dual-mass flywheel
Removing and installing Page 13
-29
Removing and installing needle bearing
Page 13
-35

4 -
Crankshaft bearing
Checking axial and radial clearance
Page 13
-21

5 -
Bolt, tightening torque 10 Nm
6 -
Oil spray jet
For piston cooling
7 -
Oil seal for rear sealing flange Replacing Page 13
-23
Pa
ge 2 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
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13-16


8 -
Bolt, tightening torque 10 Nm
9 -
Rear sealing flange
10 -
Gasket
11 -
Bolt, tightening torque 25 Nm
Screw in bolts on left and right sides finger-
tight before tightening bolts on main
bearing caps.
12 -
Cylinder block
13 -
Gasket
Pa
ge 3 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
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13-17


14 -
Collar bolt, tightening torque 30 Nm
Apply Loctite when installing
15 -
Bolt, tightening torque 10 Nm
16 -
Front sealing flange
17 -
Expansion pins
18 -
Crankshaft
Checking Page 13
-21
19 -
Chain sprocket for oil pump
Removing and installing Page 17
-62
.
20 -
Pistons
Checking Page 13
-36
Pa
ge 4 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-18


21 -
Piston rings
Checking Page 13
-36
22 -
Circlip for piston pin
23 -
Piston pin
24 -
Connecting rod
Mark cylinder number and installation
position of matching connecting rods and
bearing caps before removing Installation position: wider, slightly convex
machined surfaces on the same side
25 -
Connecting rod bearing Do not interchange used bearing shells.Connecting rods, connecting rod bearings
Page 13
-39

Pa
ge 5 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-19


26 -
Connecting rod bearing bolts
Always replaceTightening torque: 30 Nm + 90 (
1/4turn)
When measuring radial clearance, tighten
to 20 Nm but do not turn further.
27 -
Main bearing cap Marking -1- on oil pump sideReplace bolts for main bearing capsWatch position of dowel sleevesChecking bearing clearance Page 13
-21
28 -
Bolts for main bearing caps
Always replaceTightening torque Page 13
-20
Tightening sequence Page 13
-20Pa
ge 6 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-20

Crankshaft bearing caps, installing


- Bearing -1- is at the toothed belt end; bearing -4-
is at the flywheel end.

Tightening sequence:
- Stage 1 Tighten all bolts in the sequence shown (1 - 16) to 30 Nm.
- Stage 2 Tighten all bolts in the sequence shown (1 - 16) to 60 Nm.
- Stage 3 Using a fixed wrench, turn all bolts in the sequence shown (1 -
16) 90 further. - Tighten bolts -A- to 25 Nm.
Pa
ge 7 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-21

Crankshaft axial and radial clearance,
measuring


Axial clearance

Note:
Do not interchange used bearings.

- Attach dial gauge with universal dial gauge bracket VW 387 to oil pump
and bring it into contact with crank web.
- Press crankshaft against dial gauge by hand and set gauge to -0-.
- Press crankshaft away from dial gauge.
- Note reading:Clearance when new
Wear limit
0.090 ... 0.251 mm 0.28 mm
Pa
ge 8 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-22

Radial clearance

Measure radial clearance with Plastigage .
- Read value:

Clearance when new
Wear limit
0.018 ... 0.045 mm 0.10 mm
Pa
ge 9 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-23

Crankshaft oil seals, replacing


A - Toothed belt end

- Remove toothed belt Page 13-4 .

- Remove toothed belt sprocket from crankshaft

Note:
Do not lubricate sealing lip or outer circumference of seal before pressing
in. - Pull out oil seal with oil seal extractor 3203.
- Clean contact surface and sealing surface.
- Push on seal using fitting sleeve 3202/1.

- Press in seal until flush using fitting sleeve 3265 and central bolt.
Pa
ge 10 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
11/21/2002 htt
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yp
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