Dismantling and assembling engine: Audi 1.6 (BAH)

Notes:

Secure engine and gearbox support VW 540 to assembly support before carrying out assembly work.
If large quantities of swarf are found in the engine oil during engine repair (this could be caused by partial seizure of the crankshaft bearings or conrod bearings), not only are the oil passages to be thoroughly cleaned, but the oil filter should also be replaced in order to prevent subsequent damage from occurring.
All bearing and running surfaces must be oiled before assembling.

I
=>Page
13-2

II
=>Page
13-6

Part I

Toothed belt guard - upper part
Toothed belt
Mark D.O.R. before removing
Check for wear
Do not kink
Removing, installing and tensioning
=> Page
15-11

20 Nm + 1/4 turn (90 °) further
Renew
To loosen and tighten, hold with retainer 3036

Camshaft sprocket
When installing note fixing arrangement
Note position when installing the toothed belt
=> Page
15-11

10 Nm
Install with D6

Rear toothed belt guard
Coolant pump
With integrated seal
Seal must not be separated from coolant pump
Replace damaged or leaking coolant pump together with seal
Check for ease of movement
Removing and installing
=> Page
19-23

Tensioning roller
Checking=>Page
15-7
Removing, installing and tensioningtoothed belt
=>Page
15-11

20 Nm

20 Nm
Engine bracket
Crankshaft toothed belt sprocket
Note position when installing the toothed belt
=> Page
15-11

50 Nm
10 Nm
Belt pulley
When installing note fixing arrangement
Removing and installing
=> Page
15-11
; Removing, installing and tensioning toothed belt
Removing and installing ribbed belt => Page
13-9

20 Nm

Ribbed belt
Mark direction of rotation before removing
Removing and installing ribbed belt => Page
13-9
Ribbed belt routing
=> Page
13-11
Vehicles with air conditioning system have an additional idler roller

90 Nm + 1/4 turn (90 °) further
Renew
Counter-hold with 3415 to loosen and tighten
The turning further can be done in several stages
The turning further angle can be checked with a commercial protractor e.g. Hazet 6690

Toothed belt guard - lower part

Part II

Note:

Servicing the clutch:

=> Repair group 30; Servicing clutch; Removing and installing clutch
4-Cylinder engine (2-valve, roller rockers), Mechanics
Servicing clutch
Removing and installing clutch

Cylinder block
Removing and installing crankshaft => Page
13-36
Dismantling and assembling pistons and conrods
=> Page
13-41

50 Nm
Tightening sequence:
Upper right bolt first, then lower right bolt, and bolts on left last (as seen from direction of travel)

Oil filter
Loosen at hexagon flats
Tighten by hand
Note instructions on filter when installing

M8: 20 Nm + 1/4 turn (90 °) further,
M10: 45 Nm
10 Nm +1/4turn (90°) further
Renew
Unscrew securing bolts for sump/cylinder block at belt pulley end (4 bolts) from inside sump

Sump
Two-piece sump
Clean sealing surface before installing
Insert with silicone sealant
D 176 404 A2
To remove and install, remove sump tray
Removing and installing
=> Page
17-9

Oil drain plug, 30 Nm
With attached seal
Renew

Compact bracket
For vane pump and alternator
For vehicles without air conditioning system
Vehicles with air conditioning system have an additional idler roller
Removing and installing compact bracket on vehicles with air conditioner:

=> Heating, Air conditioning; Repair group 87
Heating, Air conditioning

Tensioning element
For ribbed belt
To slacken ribbed belt, turn tensioning device using spanner AF 16mm
Removing and installing ribbed belt=> Page
13-9

Bracket
For connectors

40 Nm