Seal flange and driven disk
I
- 1. Cylinder block
- 2. Seal flange with lip seal. Do not lubricate the working edge of the oil seal. For installation, use the support sleeve included in the delivery kit. Before installation, remove any remaining oil on the crankpin with a clean rag
- 3. Bolt
- 4. Driven disk. To weaken the cre
- Secure the pin bolts using -3067-
- 5. Bolt. 60 Nm + 90°. Replace
- 6. Needle bearing. Press out and press in
- 7. The intermediate shield must be installed on the mounting sleeves. Do not damage/bend during installation work. Suspended from flange
- 8. Guide sleeve
![](https://www.audimanual.ru/img/q/0293.jpg)
Tightening sequence
Tighten bolts -1. 8 - as shown in Fig. sequences:
![](https://www.audimanual.ru/img/q/0294.jpg)
- 1. Screw in the bolts by hand.
- 2. Tighten the bolts to a torque of 9 Nm.
Installation of the intermediate shield
Hang the intermediate plate on the sealing flange and push it onto the mounting sleeves -arrows-.
![](https://www.audimanual.ru/img/q/0295.jpg)
Crankshaft
II
- 1. Cylinder block
- 2. Bearing shell installed in the cylinder block with an lubrication groove. Do not replace previously used bearing shells (mark when removing)
- 3. Crankshaft. After removal, position it so that the sensor gear - pos. 5- was not adjacent to it and could not be damaged. When measuring the radial clearance, do not twist the crankshaft
- 4. Bearing shell installed in the bearing cap without an lubrication groove. Previously used bearing shells are in place. Do not change (mark when removing)
- 5. Bolt. Replace
- 6. Bearing cover. Bearing cover 1: crankshaft pulley side. The retaining lugs of the bearing shells in the cylinder block and bearing caps must lie on top of each other
- 7. Bolt. 10 Nm + 90e. Replace. Replace the sensor gear after each loosening of the bolts
- 8. Ring gear for engine speed sender -G28-. Installation is possible only in one position - the holes are offset-. Replace the sensor gear after each loosening of the bolts
- 9. Thrust half rings for bearing 3
- 10. Bolt. Replace
Sequence of tightening torques
Tighten the crankshaft bolts in the sequence -1...5- as follows.
![](https://www.audimanual.ru/img/q/0296.jpg)
- 1. Screw in bolts -1...10- and -arrows- by hand.
- 2. Pre-tighten bolts -1...10- to a torque of 65 Nm.
- 3. Bolts -1...10- tighten by 90" hard key.
- 4. Pre-tighten the bolts -arrows- to 20 Nm.
- 5. Tighten the bolts -arrows- 90°using a hard wrench.
Matching crankshaft bearings (classification)
At the factory, bearing shells of the required thickness are selected for the cylinder block. Colored marks are used to indicate the thickness of the bearing shells. Information about which bearing to install where in the cylinder block (upper bearing shell), is indicated on the bottom surface of the seal and on the end of the cylinder block using letter markings. Information about which bearing, where to install in the bearing cap (lower bearing shell), is indicated on the crankshaft using letter markings. The first letter corresponds to the first bearing cap, the second to the second, etc.
![](https://www.audimanual.ru/img/q/0297.jpg)
Designation of cylinder block bearing shells
The cylinder block marking may be located on the oil pan seal surface or on the end wall (from the CP side) cylinder block. Cylinder block markings indicate the conformity of the upper bearing shells (bearing shell, cylinder block side). Write down the letter and use the table to determine the color marking of the liner to be installed.
![](https://www.audimanual.ru/img/q/0298.jpg)
Designation of bearing shells on the cover:
The crankshaft marking indicates the conformity of the lower bearing shells (bearing shell from bearing cap side). Write down the letter and use the table to determine the color marking of the liner to be installed.
![](https://www.audimanual.ru/img/q/0299.jpg)
S=black/R=red/G=yellow/B=blue/W=white
Pistons and connecting rods
- 1. Bolt securing the connecting rod cover. 45 Nm + additional rotation by 90°. Replace. Lubricate the threads and contact surface with oil. Use old bolts to check radial runout. To measure the radial clearance, tighten by 30 Nm, but do not tighten
- 2. Connecting rod cover. Install in proper position. Thanks to the constructive fracture method (cracking) For connecting rods, the connecting rod cap is installed in only one position and only on the corresponding connecting rod. Mark cylinder accessory -A-. Location: marks -B- facing the pulley
- 3. Bearing shells. Do not replace previously used bearing shells (mark when removing). Axial displacement of the new part: 0.10...0.35 mm Limit tolerance: 0.40 mm. Radial runout measured with Plastigage: new: 0.02...0.06 mm, maximum wear tolerance: 0.09 mm. When measuring radial runout, do not turn the crankshaft
- 4. Safety valve. 27 Nm
- 5. Oil injection nozzle for piston cooling
- 6. Retaining ring. Replace
- 7. Piston pin
- 8. Piston. Mark the installation position and cylinder accessory. The arrow on the piston crown points towards the belt pulleys. Checking pistons, piston rings and cylinder diameters
- 9. Compression rings. Remove and install using piston ring pliers. Place locks offset by 120°. Mounting position: mark "TOP" or the inscribed side faces the piston crown
- 10. Oil scraper ring. 2-component. Install the upper ring lock with an offset of 120°relative to the adjacent compression ring. Mark "TOP" or "R" should be directed towards the piston crown. Before installation, move the locks of the oil scraper ring bands apart relative to each other. The height gap cannot be measured
- 11. Connecting rod. Replace only the entire set. Mark cylinder accessory -A-. Location: marks -B- facing the pulley
Mounting position of the bearing shell
![](https://www.audimanual.ru/img/q/0300.jpg)
Place the bearing shells coaxially into the connecting rod and connecting rod cap. The size -a- must be the same on the left and right.
Disconnect new connecting rod: New connecting rods may not be completely detached at the programmed break points. Do not remove the connecting rod cover by hand, proceed according to the following instructions: note the correspondence of the cylinders and connecting rods. Apply light tension to the connecting rod as shown in the figure using a vice with protective jaw pads.
![](https://www.audimanual.ru/img/q/0301.jpg)
The connecting rod tension should not be too strong to avoid damage. The connecting rod drops below the dotted line. Unscrew both bolts -arrows- approximately 5 turns. Carefully give several blows with a plastic hammer in the -direction of the arrow- opposite to the connecting rod cover until the cover comes loose.
![](https://www.audimanual.ru/img/q/0302.jpg)
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