air conditioning AUDI A8 1999 D2 / 1.G AHA ATQ Engines Cylinder Block Crankshaft And Flywheel Component Service Manual

13-10

Installing

Note:
Observe previously marked direction of rotation of belt and that it is
seated correctly on the pulley.
Routing of ribbed belt: - First install ribbed belt onto crankshaft pulley and idler wheel. Push belt
onto tensioning roller last.
D1 - without air conditioning
D2 - with air conditioning
- Remove 3204 drift.
- Install engine cover.Tightening torque for viscous fan
Tightening
torque
1331 torque wrench and 3312 open-end spanner 37 Nm (27 ft lb)
1331 torque wrench without 3312 open-end
spanner 70 Nm (52 ft lb)
Pa
ge 9 of 33 C
ylinder block, crankshaft and fl
ywheel, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.13.2

13-28
Crankshaft dimensions

Engine codes AHA, ATQ
Reconditioning dimension
Crankshaft journal diameter mm (in.)
Connecting rod journal diameter mm (in.)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
Standard (nominal dimension) 65.00 (2.559) 54.00 (2.126)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
1st undersize (nominal dimension) 64.75 (2.549) 53.75 (2.116)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
2nd undersize (nominal dimension) 64.50 (2.539) 53.50 (2.106)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
maximum size (from nominal) -0.022 (0.00087) -0.022 (0.00087)
3rd undersize (nominal dimension) 64.25 (2.530) 53.25 (2.096)
minimum size (from nominal) -0.042 (0.00165) -0.042 (0.00165)
Pa
ge 27 of 33 C
ylinder block, crankshaft and fl
ywheel, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.13.2

13-30

Piston and cylinder bore dimensions

Reconditioning
dimension Piston diameter
Basic dimension 82.48 mm (3.247
in.)
1st oversize 82.74 mm (3.257
in.)

Checking piston ring side clearance
Clearance when new
Wear limit
0.02-0.08 mm (0.0008-0.0031 in.) 0.10 mm (0.004 in.)
Pa
ge 29 of 33 C
ylinder block, crankshaft and fl
ywheel, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.13.2

13-32

Cylinder bore, checking


Piston and cylinder bore dimensions
Engine codes AHA, ATQ
Note:
Replacement pistons are only available in the basic dimension.
CAUTION!
DO NOT measure cylinder bore dimensions while the cylinder block
is mounted on the engine stand. The cylinder block is stressed and
deformed by its own weight under these conditions and the
measurements will not be accurate. - Measure at three locations diagonally in crosswise direction -A- and
lengthwise direction -B-.
Inner bore gauge: 50-100 mm (1.96-3.94 in.)
Deviation from nominal size: max. 0.08mm (0.0031 in.)Reconditioning
dimension Piston diameter
Cylinder bore
diameter
Basic dimension 82.48 mm (3.2472
in.) 82.51 mm (3.2484
in.)
1st oversize 82.74 mm (3.2575
in.) 82.76 mm (3.2578
in.)
Pa
ge 31 of 33 C
ylinder block, crankshaft and fl
ywheel, servicin
g
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE03.13.2