1996 AUDI A4 APB Engine Cylinder Block Crankshaft And Flywheel Assembly Manual

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
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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
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13-24

B - Flywheel end

Note:
Replace oil seal together with sealing flange.

Vehicles with manual transmission

- Drain off coolant Page 19
-19
.

- Remove transmission.

Repair Manual, 6 Spd. Manual Transmission
01E, Repair Group 34


- Remove clutch.

- With crankshaft at TDC, screw in clamping bolt 3242.
- Mark position of flywheel relative to engine -arrows-.
- Remove dual-mass flywheel.
- Remove sealing flange.
Pa
ge 11 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-25

Installing

- Install sealing flange.

- Install dual-mass flywheel with new bolts.

Note:
Always replace securing bolts for dual-mass
flywheel.

- Install clutch.

Repair Manual, 6 Spd. Manual Transmission
01E, Repair Group 30


Tightening torques

Dual-mass flywheel to
crankshaft 60 Nm + 180
Clutch to dual-mass flywheel 20 Nm
Pa
ge 12 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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yp
e=re
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13-26

Vehicles with automatic transmission

- Remove transmission.

Repair Manual, 5 Spd. Automatic
Transmission 01V, Repair Group 37


- Drain off coolant Page 19
-19
.

Note:
Turn over the engine at the central bolt on the crankshaft.
CAUTION!
Injury risk - do not turn engine while feeling for TDC drilling. - Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.
- Check position of camshafts: larger holes in securing plates on
camshaft sprockets must align opposite one another on inside. If this is
not the case, turn crankshaft one revolution further.
- Remove sealing plug from cylinder block, left.
- The TDC drilling in crankshaft must be visible (or able to be felt) in line
with sealing plug hole.
Pa
ge 13 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-27


Installing - Screw clamping bolt 3242 for crankshaft into sealing plug hole and
tighten.
- Mark positions of holes in drive plate, shim -1- and washer -2- in
relation to crankshaft.
- Mark positions of shim -1- in front of drive plate and washer -2- behind
drive plate.

Note: - Install drive plate with washer -2- and shim -1- (3.0 mm or 4.0 mm).
Short engines and exchange engines are supplied without bush in
crankshaft. On vehicles with automatic transmission, always knock in
new bush before installing drive plate. Always replace drive plate securing bolts.
Pa
ge 14 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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yp
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13-28

Tightening torques

Drive plate to crankshaft
60 Nm + 90

Note:
Always replace securing bolts for drive plate.

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. 29.9 mm.
- Install a different shim if necessary.
- Install transmission.
Pa
ge 15 of 26 C
ylinder block, crankshaft and fl
ywheel, disassembl
y and assembl
y
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13-29

Dual-mass flywheel / drive plate,
installation dimensions, removing and
installing


A - Flywheel

Removing

- Remove transmission.

Repair Manual, 6 Spd. Manual Transmission
01V, Repair Group 34

- Remove clutch.

- With crankshaft at TDC, screw in clamping bolt 3242.
- Mark position of flywheel relative to engine -arrows-.
- Remove bolts (bolts must be replaced).
Pa
ge 16 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