AUDI A8 1997 D2 / 1.G AHA ATQ Engines Cylinder Block Crankshaft And Flywheel Component User Guide
Manufacturer: AUDI, Model Year: 1997, Model line: A8, Model: AUDI A8 1997 D2 / 1.GPages: 33, PDF Size: 0.75 MB
Page 11 of 33

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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Page 12 of 33

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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Page 13 of 33

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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Page 14 of 33

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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Page 15 of 33

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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Page 16 of 33

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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Page 17 of 33

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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Page 18 of 33

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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Page 19 of 33

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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Page 20 of 33

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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11/21/2002 htt
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