1996 AUDI A4 AFC Engine Cylinder Block Crankshaft And Flywheel Component Assembly Manual

13-6


Cylinder block, crankshaft and
flywheel, component layout Note:
Always replace gaskets and seals.
1 -
Main bearing cap bolts
Always replaceTightening torque: 60 Nm (44 ft lb) plus
1/2-turn (180 )
2 -
Main bearing cap
ID: "1" on side facing oil pumpAlways replace boltsChecking bearing clearance page 13
-21
3 -
Connecting rod bearing cap bolts
Always replaceTightening torque: 30 Nm (22 ft lb) plus
1/4-turn (90 ) Tighten to 20 Nm (15 ft lb) for measuring
radial clearance, but do NOT tighten further
4 -
Connecting rod bearing shells Never interchange used connecting rod
bearing shells
Pa
ge 1 of 32 C
ylinder block, crankshaft and fl
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ponent la
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Checking connecting rods and bearings
page 13
-31

Pa
ge 2 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
yout
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13-7


5 -
Piston rings
Checking page 13
-25
6 -
Piston
Checking page 13
-26
7 -
Crankshaft
Checking page 13
-21
Dimensions page 13
-24
8 -
Oil pump
Check drive gear on crankshaft when
installing Removing Repair Group 17
9 -
10 Nm (7 ft lb)
10 -
Thrust washers
Installed only at 4th crankshaft main
bearing Checking crankshaft axial clearance
page 13
-21

11 -
Bolt
Automatic trans. (drive plate)
Always replaceTightening torque: 60 Nm (44 ft lb) plus
1/4-turn (90 )
Pa
ge 3 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
yout
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.13.4

Manual trans. (flywheel)
Always replaceTightening torque: 40 Nm (30 ft lb) plus
1/2-turn (180 )
Pa
ge 4 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
yout
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.13.4

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
ge 5 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
yout
11/21/2002 htt
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play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.13.4

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-
Pa
ge 6 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
yout
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e=re
pair&id=AUDI.B5.GE01.13.4

D1 - Without air conditioner
D2 - With air conditioner
Pa
ge 7 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
yout
11/21/2002 htt
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play?action=Goto&t
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13-10

Vibration damper, removing and
installing


Removing
Removing ribbed belt page 13
-9 .

Note:
The center bolt does not have to be loosened to
remove the vibration damper.

- Remove vibration damper.

Installing

- When installing, make sure that notch (arrow) in vibration damper is
aligned with locking lug on toothed belt sprocket.
Tightening torque: 25 Nm (15 ft lb)
Pa
ge 8 of 32 C
ylinder block, crankshaft and fl
ywheel, com
ponent la
yout
11/21/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE01.13.4