Removing and installing crankshaft, flywheel/drive plate and sealing flanges — AUDI

Notes:

Servicing clutch

=> 5-speed Manual Gearbox 012 Front-wheel Drive; Repair Group 30; Servicing clutch
5-speed Manual Gearbox 012 Front-wheel Drive
Servicing clutch

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

O-ring/gasket
Depending on design status
Replace

Lock washer
Depending on design status
Replace

10 Nm
Apply locking fluid "D 000 600 A2" when fitting bolts of oil pump and idler wheel

Suction pipe
Attach to oil pump first

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

65 Nm

60 Nm + further 1/4 turn (90°)
Replace

Ball bearing
Replace in the event of rough running/stiffness
Extracting and driving in=>Page
13-73

Flywheel/drive plate
Removing and installing flywheel
=> Page
13-70
Removing and installing drive plate
=> Page
13-71
Subsequent production of ignition point notch => Fig.
13-66

Oil seal
Cannot be replaced separately

Rear sealing flange
With oil seal
Replace only as complete assembly
Lubricate sealing lip of oil seal slightly
Before fitting sump, apply thin coat of sealant "AMV 174 004 01" to sealing flange/cylinder block transitions

Gasket
Replace

Crankshaft
As-new axial clearance: 0.07...0.23 mmWear limit: 0.25 mm
Measure radial clearance with Plastigage
As-new: 0.018...0.058 mm
Wear limit: 0.10 mm
Do not turn crankshaft when measuring radial clearance
Crankshaft dimensions=> Page
13-75

Thrust washer
For bearing cap, bearing 3
Pay attention to locator

Bearing shell 3
For bearing cap with no oil groove
For cylinder block with oil groove
Do not interchange used bearing shells (mark)

Thrust washer
For cylinder block (without retainer tabs)
Pay attention to locator

Bearing shells 1, 2, 4 and 5
For bearing cap with no oil groove
For cylinder block with oil groove
Do not interchange used bearing shells (mark)

Gasket
Replace

Oil pump
Removing and installing=>Page
17-15
Watch out for driver at crankshaft on installation

Oil seal
For crankshaft
Removing and installing=>Page
13-67

20 Nm

Fig.1
Subsequent production of ignition point notch

Note:

Replacement flywheels/drive plates are supplied with TDC mark "0" only. Ignition point notch must be produced after replacing flywheel/drive plate.

Scribe ignition point notch, working to left from centre of TDC mark. To do so, measure arc dimension.
Dimension a = 36.5 mm

Note:

Dimension "a" corresponds to an ignition point of 15° before TDC.