Removing and installing crankshaft, flywheel and sealing flanges — AUDI

Notes:

Servicing clutch

=> 5 and 6-speed Manual Gearbox 01E Four-wheel Drive; Repair Group 30; Servicing clutch
5 and 6-speed Manual Gearbox 01E Four-wheel Drive
Servicing clutch

For performing assembly work, engine is to be attached with engine holder VW 540 to repair stand.

O-ring
Replace

Lock washer
Depending on design status
Replace

10 Nm
Apply locking fluid when fitting
Locking fluid

=> Parts List

Suction pipe
Attach to oil pump first

10 Nm
Bearing cap
Bearing cap 1: Pulley end
Retainer tabs of cylinder block/bearing cap bearing shells must coincide

65 Nm
Dual-mass flywheel
Removing and installing dual-mass flywheel => Page
13-51
Can only be fitted in one position
-offset holes-
Checking distance between engine speed sender -G28 and dual-mass flywheel => Fig.
1
With welded-on lugs for ignition point and timing => Fig.
2
Checking distance between firing point sender -G4 and lugs at dual-mass flywheel=> Fig.
3

40 Nm + further 180° (1/2) turn
Replace

Needle bearing
Extracting and driving in=>Page
13-52

10 Nm
Oil seal
Only available together with -item
13
-

Rear sealing flange
With oil seal
Removal and installation involve taking out sump => Page
17-12
Before fitting sump, apply thin coat of sealant to sealing flange/cylinder block transitions
Sealant

=> Parts List

Gasket
Replace
Fit only if sealing flange has no sealing lip on cylinder block end

Crankshaft
As-new axial clearance: 0.07...0.23 mm Wear limit: 0.30 mm
Measure radial clearance with Plastigage
As-new: 0.018...0.058 mm
Wear limit: 0.16 mm
Do not turn crankshaft when measuring radial clearance
Crankshaft dimensions
=> Page
13-54

Thrust washer
For bearing cap
Pay attention to locator

Bearing shell
For bearing cap with no oil groove
Do not interchange used bearing shells (mark)

Thrust washer
For bearing cap
Pay attention to locator

Thrust washer
For cylinder block (without retainer tabs)

Bearing shell
For cylinder block with oil groove
Do not interchange used bearing shells (mark)

Thrust washer
For cylinder block (without retainer tabs)

Bearing shell
For bearing cap with no oil groove
For cylinder block with oil groove
Do not interchange used bearing shells (mark with waterproof felt-tip pen)

Gasket
Replace

Oil pump
Removing and installing
=> Page
17-17
Watch out for driver at crankshaft on installation

Oil seal
For crankshaft
Removing and installing
=> Page
13-49

10 Nm
20 Nm

Fig.1
Checking distance between engine speed sender -G28 and dual-mass flywheel

Screw in engine speed sender -G28.
Use feeler gauge to check distance between splines of dual-mass flywheel and engine speed sender.
Specification: 0.50 ... 1.25 mm

Fig.2
Lugs at dual-mass flywheel

Lugs -1- and -2- for ignition timing (for ignition tester)
Lug -3- for ignition point (for firing point sender -G4)

Fig.3
Checking distance between firing point sender -G4 and lugs at dual-mass flywheel

Turn dual-mass flywheel until lug is positioned beneath opening of firing point sender.

Screw in firing point sender -G4.
Use feeler gauge to check distance between lug and firing point sender.
Specification: 0.45 ... 1.25 mm