2.0l - Crankshaft, Cylinder Block - Engine Code(s): Cbfa & Ccta Audi A3 8P рестайлинг 2

CRANKSHAFT BEARING SHELLS ALLOCATION

The bearing shells are allocated to the cylinder block with the correct thickness at the factory. Colored spots serve to identify the bearing thicknesses.

The code letters on the lower contact surface or on the top of the cylinder block identify which bearing shell and where it must be mounted on the cylinder block (upper bearing shell).

The code letters on the crankshaft identify which bearing shells and where they must be installed in the bearing cover (lower bearing shell).

The first letter is for bearing cover one, the second for bearing cover two, etc.

Cylinder block bearing shell identification

Note. The cylinder block identification may be located either on the oil pan sealing surface or on the top (transmission side) of the cylinder block.

The identification on the cylinder block is for the upper bearing shell.

Scheme 289

Note the letters and then match it to the color identification in the table.

Bearing cap bearing shell identification

The identification on the crankshaft is for the lower bearing shell.

Scheme 290

Note the letters and then match it to the color identification in the table.

Scheme 291

1. Vibration Damper With ribbed belt pulley Removing and installing, refer to «VIBRATION DAMPER»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__vibration-damper)
2. O-ring Replace
3. Bolt Replace 150 Nm plus an additional 90° turn Coat the O-ring with oil. Usecounter hold tool T10355 to loosen and tighten CAUTION: Danger of causing damage to the engine. D.o not turn the crankshaft when a bolt is removed because this will offset the timing.
4. Ribbed Belt Check for wear Do not kink CAUTION: Risk of destroying due to reversed running direction on a used ribbed belt. Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later. Removing and installing, refer to «RIBBED BELT»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__ribbed-belt) When installing, make sure it is seated correctly on the pulleys
5. Ribbed Belt Tensioning Damper Move the damper using a open-end wrench to release the tension on the ribbed belt Secure with locking pin T10060 A Tensioning device for ribbed belt «RIBBED BELT DRIVE ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta) Removing and installing, refer to «RIBBED BELT TENSIONER»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__ribbed-belt-tensioning-damper)
6. Auxiliary Components Bracket With oil filter and engine oil cooler Accessory Assembly Bracket, Removing and Installing, refer to «ACCESSORY ASSEMBLY BRACKET»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__auxiliary-components-bracket) For removing and installing engine oil cooler, refer to «ENGINE OIL COOLER»(/audi/a3/8p-2-2008-2013/remont/lubrication-system/#20l-lubrication-engine-codes-cbfa-ccta__engine-oil-cooler)
7. Bolt 10 Nm
8. Generator Removing and installing, refer to «Removal and Installation»(/audi/a3/8p-2-2008-2013/remont/charging-system/#battery-starter-generator-cruise-control-general-information)
9. Bolt Tightening specifications, refer to «Specifications»(/audi/a3/8p-2-2008-2013/remont/charging-system/#battery-starter-generator-cruise-control)
10. Bolt Tightening order «RIBBED BELT DRIVE ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta)
11. A/C Compressor Do not remove or disconnect refrigerant lines Removing and installing, refer to «Removal and Installation»(/audi/a3/8p-2-2008-2013/remont/automatic-hvac-system/#air-conditioning)
12. Bolt 25 Nm
13. Alignment Sleeve For air conditioning compressor

Scheme 292

1. Ribbed belt tensioning damper
2. Support
3. Auxiliary components bracket
4. Centering sleeve
5. Bolt

Scheme 293

Mount the accessory assembly bracket and then mount the bolts -4-.

Tighten bolts in 3 stages in -1 to 5- sequence as follows

Scheme 294

1. Cylinder Block Removing and installing crankshaft, refer to «CRANKSHAFT ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-overview) Piston and connecting rod, disassembling and assembling, refer to «PISTONS AND CONNECTING ROD ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta)
2. Fitting Pin
3. Transmission Side Sealing Flange With seal Only replaced as complete unit Removing and installing, refer to «TRANSMISSION-SIDE SEALING FLANGE»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__sealing-flange-transmission-side) Do not oil or grease the sealing lip of oil seal Before installing, remove oil remains from crankshaft journal with a clean cloth Guide sleeve may only be removed after the sealing flange has been slid onto the crankshaft pin.
4. Bolt Tightening order «TRANSMISSION-SIDE SEALING FLANGE AND DUAL-MASS FLYWHEEL ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta)
5. Intermediate Plate Must be located on dowel sleeves Do not damage or bend when doing assembly work Is hooked in at sealing flange «TRANSMISSION-SIDE SEALING FLANGE AND DUAL-MASS FLYWHEEL ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta)
6. Bolt Replace 60 Nm plus an additional 90° turn For dual-mass flywheel/drive plate
7. Dual Mass Flywheel Dual Mass Flywheel, Removing and Installing, refer to «DUAL MASS FLYWHEEL»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__dual-mass-flywheel) . Only possible to install in one position. The holes are offset.
8. Fitting Pin

Scheme 295

Tighten the bolts -1 through 8- in the sequence shown

1. Tighten the bolts hand-tight.

2. Tighten the bolts to 9 Nm.

Scheme 296

Hook in intermediate plate at sealing flange and push it onto the alignment sleeves -arrows-.

CRANKSHAFT OVERVIEW

Note. Secure engine to assembly stand using engine and transmission holder VAS 6095 when performing repair work. Refer to ENGINE, SECURING ON ASSEMBLY STAND .

Scheme 297

1. Cylinder Block
2. Bearing Shell for Cylinder Block With lubricating groove Do not interchange used bearing shells (mark) Crankshaft bearing shell identification, refer to «CRANKSHAFT BEARING SHELLS ALLOCATION»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-bearing-shells-allocation)
3. Crankshaft After removal, place in such a way it does not rest on sensor wheel -5- and damage it If the crankshaft is being replaced, then the bearing shells must be allocated to the bearing cover, refer to «CRANKSHAFT BEARING SHELLS ALLOCATION»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-bearing-shells-allocation) Axial clearance, refer to «CRANKSHAFT, MEASURING AXIAL PLAY»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-axial-clearance-measuring) Radial clearance, refer to «CRANKSHAFT, MEASURING RADIAL PLAY»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-radial-clearance-measuring) Do not turn crankshaft when measuring radial play Crankshaft dimensions, refer to «CRANKSHAFT DIMENSIONS»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-dimensions)
4. Bearing Shell for Bearing Cap Without lubricating groove Do not interchange used bearing shells (mark) Crankshaft bearing shells identification (classification), refer to «CRANKSHAFT BEARING SHELLS ALLOCATION»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-bearing-shells-allocation)
5. Bolt Replace Tightening order «CRANKSHAFT ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-overview)
6. Bearing Cap Bearing cap 1: belt pulley side Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
7. Bolt Replace 10 Nm plus an additional 90° turn Replace sensor wheel every time bolts are loosened, refer to «SENSOR WHEEL»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__sensor-wheel)
8. Sensor Wheel For engine speed (RPM) sensor -G28- It is possible to install in one position only, the holes are offset. Replace sensor wheel every time bolts are loosened Removing and installing, refer to «SENSOR WHEEL»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__sensor-wheel)
9. Thrust Washers For bearing 3
10. Bolt Replace Tightening order «CRANKSHAFT ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-overview)

Scheme 298

Tighten the crankshaft bolts in the sequence -1 to 5-.

Tighten the bolts -1 through 10- and -arrows- hand-tight.

Tighten the bolts -1 through 10- to 65 Nm.

Tighten the bolts -1 through 10- 90° further using a rigid wrench.

Tighten the bolts -arrows- to 20 Nm.

Tighten the bolts -arrows- 90° further using a rigid wrench.

Scheme 299

1. Connecting Rod Bolt Replace 45 Nm plus an additional 90° Lubricate the threads and contact surface Use old bolt to measure radial play Tighten to 45 Nm to measure radial play, do not turn further
2. Connecting Rod Bearing Cap Pay attention to the installed position. Due to the separation procedure (cracking) of the connecting rod, the cap only fits in one position and only to the corresponding connecting rod. Mark affiliation to cylinder -A- Installed position: the markings -B- face the belt pulley side Separate new connecting rod, refer to «CONNECTING ROD, SEPARATING NEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__connecting-rod-separating-new)
3. Bearing Shells Installed position, refer to «PISTONS AND CONNECTING ROD ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta) Do not interchange used bearing shells (mark) Axial play new: 0.10 to 0.35 mm, wear limit: 0.40 mm Measure radial clearance with Plastigage, new: 0.02 to 0.06 mm, wear limit: 0.09 mm Do not turn crankshaft when checking radial clearance
4. Pressure Relief Valve 27 Nm
5. Oil Spray Jet For piston cooling
6. Locking Ring Replace
7. Piston Pin Coat with oil before installing
8. Piston Removing and installing, refer to «PISTONS»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__pistons) Mark installed position and cylinder allocation Arrow on piston face points toward belt pulley side Piston and cylinder bore, checking, refer to «PISTONS AND CYLINDER BORE, CHECKING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__pistons-and-cylinder-bore-checking)
9. Compression Rings Offset gaps by 120° Use piston ring pliers (commercially available) for removing and installing Installed position: "TOP" "R" mark must face up toward piston crown Checking ring gap, refer to «PISTONS AND CYLINDER BORE, CHECKING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__pistons-and-cylinder-bore-checking) figure. Check piston ring groove clearance, refer to «PISTONS AND CYLINDER BORE, CHECKING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__pistons-and-cylinder-bore-checking) figure.
10. Oil Scraping Ring 2-part Install offset gaps by 120° to the neighboring compression ring The "TOP" or "R" marking must face toward the piston crown. Checking ring gap, refer to «PISTONS AND CYLINDER BORE, CHECKING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__pistons-and-cylinder-bore-checking) figure. Side clearance cannot be measured.
11. Connecting Rod Only replace as set Mark affiliation to cylinder -A- Installed position: the markings -B- face the belt pulley side Separate new connecting rod, refer to «NEW CONNECTING ROD, SEPARATING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__connecting-rod-separating-new) Radial clearance, measuring, refer to «CONNECTING ROD RADIAL CLEARANCE, MEASURING»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__connecting-rod-radial-clearance-measuring)

Installed Position of Bearing Shell

Place bearing shells centrally into connecting rod and connecting rod bearing cap.

Dimension -a- must be the same at left and right.

Scheme 300

Scheme 301

Push ring squarely from above down to approximately 15 mm from bottom end of cylinder. To do this use a piston without rings.

Scheme 302

Clean the piston ring groove before checking.

Scheme 303

Take measurement approximately 10 mm from lower edge of piston skirt and offset 90° to piston axis.

1. Deviation from nominal size: max. 0.04 mm.

Scheme 304

Special tools and workshop equipment required

1. Internal dial gauge 50 - 100 mm

Measure diagonally at 3 positions transversely -A- and longitudinally -B-.

1. Deviation from nominal size: max. 0.08 mm.

Note. Measurement of cylinder bore may not be performed when the cylinder block is mounted in engine and transmission holder VAS 6095, false measurements are possible.

Installed Position of Bearing Shell

Place bearing shells centrally into connecting rod and connecting rod bearing cap.

Dimension -a- must be the same at left and right.

CONNECTING ROD, SEPARATING NEW

New connecting rods may not be separated at the location where they should be. If the connecting rod bearing cap cannot be removed by hand, proceed as follows

Mark which cylinder belongs to the connecting rod -11- PISTONS AND CONNECTING ROD ASSEMBLY OVERVIEW

Lightly clamp the connecting rod in a vise equipped with aluminum protective pads.

Scheme 305

Note. Only clamp the connecting rod lightly to avoid damaging it. Clamp the connecting rod below the dotted line.

Loosen both bolts -arrows- about five turns.

Carefully tap against the connecting rod bearing cap in the direction of the -arrow- with a plastic hammer until the cap is loose.

Scheme 306

CRANKSHAFT DIMENSIONS

(Dimensions in mm)

PISTON AND CYLINDER DIMENSIONS

FASTENER TIGHTENING SPECIFICATIONS

Accessory Assembly Bracket Tightening Sequence

Mount the accessory assembly bracket and then mount the bolts -4-.

Tighten bolts in 3 stages in -1 to 5- sequence as follows

Transmission Side Sealing Flange, Tightening Sequence

Tighten the bolts -1 through 8- in the sequence shown

1. Tighten the bolts hand-tight.

2. Tighten the bolts to 9 Nm.

Crankshaft, Tightening Sequence

Tighten the crankshaft bolts in the sequence -1 to 5-.

Tighten the bolts -1 through 10- and -arrows- hand-tight.

Tighten the bolts -1 through 10- to 65 Nm.

Tighten the bolts -1 through 10- 90° further using a rigid wrench.

Tighten the bolts -arrows- to 20 Nm.

Tighten the bolts -arrows- 90° further using a rigid wrench.

CRANKSHAFT AXIAL CLEARANCE, MEASURING

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6079

Procedure

Attach VAS 6079 together with VW 387 to cylinder block and set indicator against crankshaft counterweight.

Scheme 307

Press the crankshaft against the dial gauge by hand and set the gauge to "0".

Press the crankshaft off the dial gauge and read the measurement.

Axial clearance

1. New: 0.07 to 0.23 mm.
2. Wear limit: 0.30 mm.

CRANKSHAFT RADIAL CLEARANCE, MEASURING

Special tools and workshop equipment required

1. Plastigage

Procedure

Note. Do not interchange used bearings Bearing shells that are worn down to the nickel layer must be replaced.

Remove the main bearing cap, clean the bearing cap and journal.

Place Plastigage over entire width of bearing journal or into bearing shells.

1. Plastigage must rest in center of bearing shell.

Position the main bearing cap and tighten it to 60 Nm. Do not rotate the crankshaft when doing so.

Remove main bearing cap again.

Compare width of Plastigage with calibrated scale.

Radial clearance

1. New: 0.017 to 0.037 mm.
2. Wear limit: 0.15 mm.

PISTONS AND CYLINDER BORE, CHECKING

Pistons, Checking

With an external micrometer 75 to 100 mm. Take measurement at approximately 15 mm from lower edge of piston skirt and offset 90° to piston axis.

1. Deviation from nominal size: Max. 0.04 mm.

Piston Ring Gap, Checking

Push piston ring squarely from above down to approximately 15 mm from bottom end of cylinder. To do this use a piston without rings.

Piston Ring Groove Clearance, Checking

Clean the ring groove of piston before checking.

Special tools and workshop equipment required

1. Inside Micrometer Set 18-100 mm US1033/S
2. Internal Dial Gauge VAS 6078
3. Engine and Transmission Holder VAS 6095

Using a US1033/S- or VAS 6078- measure in a diagonal sequence at 3 positions transversely -A- and longitudinally -B-.

1. Deviation from nominal size: max. 0.08 mm.

Note. Measurement of cylinder bore may not be performed when the cylinder block is mounted in VAS 6095-, false measurements are possible.

CONNECTING ROD RADIAL CLEARANCE, MEASURING

Special tools and workshop equipment required

1. Plastigage®

Procedure

Remove the connecting rod bearing cap.

Clean the bearing cap and journal.

Place the Plastigage® over the entire width of the bearing journal or into the bearing shells.

Position the connecting rod bearing cap and tighten it to 30 Nm without tightening it further; do not turn the crankshaft.

Install the connecting rod bearing cap.

Compare width of Plastigage® with calibrated scale.

Radial clearance

1. New: 0.02 to 0.06 mm.
2. Wear limit: 0.09 mm.

Replace connecting rod bolts.

RIBBED BELT

Special tools and workshop equipment required

1. Locking Pin T10060A

Removing

Disconnect the vacuum line -1- to the EVAP canister by pressing the release button.

Scheme 308

Free up the vacuum line on the coolant pipe

Note. Ignore -2-.

Remove EVAP canister with connected lines upward out of bracket -arrow- and lay aside.

Scheme 309

To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Scheme 310

Secure tensioner with T10060 A.

Remove ribbed belt.

Installing

Installation is in reverse order of removal, note the following

Note. Secure the generator and A/C compressor before installing the ribbed belt.

Place the ribbed belt onto the crankshaft, A/C and generator belt pulleys.

Scheme 311

Hold tensioner with open end wrench and remove T10060 A.

Release tensioner.

Check whether ribbed belt is routed correctly.

Start engine and check whether ribbed belt runs correctly.

RIBBED BELT TENSIONING DAMPER

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A with Spindle 10 - 222 A /11
2. Bracket for Engine 10 - 222 A /1
3. Engine Sling 2024 A
4. Lifting Eye 2024 A /2
5. Locking Pin T10060 A

Removing

Remove the noise insulation in the center by loosening the fasteners -1 and 2-.

Scheme 312

Loosen the fasteners -1, 2 and 3- and remove the right noise insulation.

Scheme 313

Remove the bolt -2- on the bracket for the after-run coolant pump -V51-.

Scheme 314

Note. Ignore -1 and arrows-.

Tighten the lifting eye 2024 A /2 on the engine lifting eye using a collar nut -arrow-.

Scheme 315

Place 10 - 222 A on upper edge of web plates with the following tool parts

Scheme 316

1. Engine brackets 10 - 222 A /1, quantity: 2
2. Spindle 10 - 222 A /11

Tension the engine with the spindle.

Remove the subframe bolts -arrows- on the engine.

Scheme 317

Lower the engine approx. 55 mm.

To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Secure tensioner with T10060 A.

Remove the ribbed belt from the tensioner.

Free up the wiring harness -arrow-.

Scheme 318

Remove the bolt -1- and remove the ribbed belt tensioner from the accessory assembly bracket.

Installing

1. Tightening specifications, refer to «RIBBED BELT DRIVE ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta) .

Installation is in reverse order of removal, note the following

Insert the ribbed belt tensioner -1- into the accessory assembly bracket -3- and tighten the bolt -5-.

1. Note the installation position of the support -2- : Insert the tabs on the support into the hole in the accessory assembly bracket.
2. Note the centering sleeve -4-.

Install ribbed belt. Refer to RIBBED BELT .

Install after-run coolant pump -V51-. Refer to AFTER-RUN COOLANT PUMP .

Adjust subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

AUXILIARY COMPONENTS BRACKET

Removing

Drain coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Remove ribbed belt. Refer to RIBBED BELT .

Remove generator. Refer to Removal and Installation .

Disconnect solenoid clutch electrical connector -1- on A/C compressor.

Scheme 319

Remove A/C compressor bolts -arrows-.

Tie up the compressor with the refrigerant lines attached to the longitudinal member.

Remove the bolt -arrow- for the oil dipstick guide tube.

Remove the bolts -1 through 5- and pull off the accessory assembly bracket from the coolant pump housing.

Installing

1. Tightening specifications, refer to «RIBBED BELT DRIVE ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to an additional torque. Replace the O-rings and seals. Coat the O-rings -4- with coolant additive.

Scheme 320

Install the connection -2- in the coolant pump housing -3-.

Press the accessory assembly bracket -1- onto the connection, mount the bolts and tighten RIBBED BELT DRIVE ASSEMBLY OVERVIEW Accessory Assembly Bracket Tightening Sequence .

Install A/C compressor. Refer to Removal and Installation .

Install generator. Refer to Removal and Installation .

Install ribbed belt. Refer to RIBBED BELT .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

VIBRATION DAMPER

Special tools and workshop equipment required

1. Locking Pin T10060 A
2. Counter Hold Tool T10355

Removing

Remove the noise insulation in the center by loosening the fasteners -1 and 2-.

Loosen the fasteners -1, 2 and 3- and remove the right noise insulation.

Remove bolts -arrows-.

Scheme 321

Remove the air guide pipe by lifting the clamps -1 and 2-.

To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Secure tensioner with T10060 A.

Remove ribbed belt from vibration damper ribbed belt pulley.

Rotate the vibration damper using the T10355 into the TDC position -arrow-.

Scheme 322

1. The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Remove vibration damper bolt using T10355.

Installing

1. Tightening specifications, refer to «RIBBED BELT DRIVE ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta) .

Installation is in reverse order of removal, note the following

Note. Replace the vibration damper bolt. Replace O-ring -1-.

Coat the sealing lip with transmission oil.

Mount the vibration damper; when doing this, pay attention to the tooth contour -arrow-.

Install ribbed belt. Refer to RIBBED BELT .

DUAL MASS FLYWHEEL

Special tools and workshop equipment required

1. Flywheel Retainer 3067

Removing

Mark the dual-mass flywheel to the engine.

Rotate dual mass flywheel -A- so bolts -B- are centered to holes -arrows-.

Scheme 323

When removing the bolts -B- make sure the bolt head does not come in contact with the dual mass flywheel -arrows- which would be damaged if the flywheel is turned further.

Insert 3067 into hole in cylinder block -B-.

Scheme 324

Remove the dual mass flywheel.

Installing

Installation is in reverse order of removal, note the following

1. Tightening specifications, refer to «TRANSMISSION-SIDE SEALING FLANGE AND DUAL-MASS FLYWHEEL ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta) .

Use new bolts.

Insert 3067 into hole in cylinder block -A-.

SEALING FLANGE, TRANSMISSION SIDE

Special tools and workshop equipment required

1. Guide Sleeve T20097
2. Hand drill with plastic brush attachment.
3. Protective eyewear

Removing

1. Transmission removed.

Remove dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

Unhook the intermediate plate at sealing flange and at the alignment sleeves -arrows-.

Remove the bolts -1 through 8

Remove the transmission side sealing flange.

Installing

1. Tightening specifications, refer to «TRANSMISSION-SIDE SEALING FLANGE AND DUAL-MASS FLYWHEEL ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta) .

Note. Note the expiration date of the silicone sealant. The sealing flange must be installed within 5 minutes after the silicone sealant has been applied.

Remove any sealant residue on the cylinder block using a flat blade scraper.

Remove remaining sealant on sealing flange using for example a rotating plastic brush.

Scheme 325

Clean sealing surfaces, must be free of oil and grease.

Cut tube nozzle at front marking (jet dia. approximately 2 mm).

Scheme 326

Apply the silicone sealant on the clean sealing surface of the cover as illustrated.

Scheme 327

1. Sealant bead thickness: 2 to 3 mm.

Note. The sealing flange must be installed within 5 minutes after the silicone sealant has been applied. The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

Position the T20097 on the crankshaft pins.

Scheme 328

Slide the sealing flange on the crankshaft flange using the T20097 and tighten the bolts right away, tightening sequence TRANSMISSION-SIDE SEALING FLANGE AND DUAL-MASS FLYWHEEL ASSEMBLY OVERVIEW .

Note. After installing sealing flange, the sealant must dry for approximately 30 minutes. Only after then may the engine oil be replenished.

The rest of the assembly is basically a reverse of the disassembling sequence.

SENSOR WHEEL

Remove engine.

Remove the transmission-side sealing flange. Refer to TRANSMISSION-SIDE SEALING FLANGE .

Remove the upper section of the oil pan. Refer to OIL PAN, UPPER SECTION .

Remove the balance shaft timing chain. Refer to BALANCE SHAFT TIMING CHAIN .

Remove the connecting rod bearing cover.

Remove the crankshaft bearing cover.

Remove the crankshaft and then remove the sensor wheel.

Always replace sensor wheel -2- whenever bolts are removed -1-.

Scheme 329

Note. After tightening a second time, the attachment point of the countersunk bolts of the sensor wheel are so deformed that the bolt heads lie on the crankshaft -3- -arrows- and the sensor wheel is loose underneath the screws. Installation of sensor wheel is only possible in one position - the bores are offset.

1. Tightening specifications, refer to «CRANKSHAFT ASSEMBLY OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta__crankshaft-overview) .

NEEDLE BEARINGS, REMOVING FROM CRANKSHAFT AND INSTALLING

Only for vehicles equipped with Automatic Transmission

Special tools and workshop equipment required

1. Puller T10055 with Adapter T10055/3
2. Centering Mandrel 3176 or Drift Piston Pin VW 207 C
3. Extractor for example: Kukko Extractor 14.5-18.5 mm -21/2

Removing

Remove with standard puller, for example Kukko21/2 -arrow-, T10055/3 and T10055.

Scheme 330

Installing

Note. Side of needle bearing with writing on it must be readable when installed.

Drive in using VW 207 C or 3176.

Scheme 331

Installation depth dimension -a- = 2 mm

Scheme 332

PISTONS

Special tools and workshop equipment required

1. Pilot Drift VW 222 A
2. Engine and Transmission Holder VAS 6095
3. Piston ring compressor, commercially available

Removing

Removing engine. Refer to

Secure engine to the VAS 6095-. Refer to

Remove the cylinder head.

Remove the upper oil pan. Refer to

Mark installed position and cylinder allocation

Mark installed position and connecting rod cylinder -item 11- PISTONS AND CONNECTING ROD OVERVIEW

Remove the connecting rod bearing cap and pull the piston and connecting rod upward.

Note. Warm the piston to approximately 60 °C (140 °F) if it is difficult to move the piston pin.

Remove the locking ring from the eye of the piston bolt.

Remove the piston pin using VW 222 A

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «PISTONS AND CONNECTING ROD OVERVIEW»(/audi/a3/8p-2-2008-2013/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-cbfa-ccta)

Note. Replace any bolts that were tightened with an additional turn. Arrow on piston face points toward belt pulley side. Offset the piston ring gap by 120°.

Coat the contact surfaces on the bearing shells with oil.

Install the piston with a piston ring compressor. Pay attention to the installed position -item 8- PISTONS AND CONNECTING ROD OVERVIEW

Install the connecting rod bearing cap. Pay attention to the installed position -item 2- PISTONS AND CONNECTING ROD OVERVIEW

Install the cylinder head

Install the upper oil pan. Refer to

Scheme 333

Special tools and workshop equipment required

1. Puller T10055 with Adapter T10055/3
2. Centering Mandrel 3176 or Drift Piston Pin VW 207 C
3. Extractor for example Kukko21/2

Special tools and workshop equipment required

Scheme 334

Scheme 335

Scheme 336

Scheme 337

Scheme 338

Scheme 339

Scheme 340

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6079
3. Locking Pin T10060A
4. Engine Support Bridge 10 - 222 A with Spindle 10 - 222 A /11
5. Engine Sling 2024 A
6. Counter Hold Tool T10355
7. Flywheel Retainer 3067
8. Guide Sleeve T20097

See also:
• ENGINE OIL COOLER
• Removal and Installation
• Specifications
• Removal and Installation
• ENGINE, SECURING ON ASSEMBLY STAND
• AFTER-RUN COOLANT PUMP
• SUBFRAME MOUNT, ADJUSTING
• COOLING SYSTEM, DRAINING AND FILLING
• OIL PAN, UPPER SECTION
• BALANCE SHAFT TIMING CHAIN
• VIBRATION DAMPER
• RIBBED BELT
• RIBBED BELT DRIVE ASSEMBLY OVERVIEW
• RIBBED BELT TENSIONER
• ACCESSORY ASSEMBLY BRACKET
• CRANKSHAFT ASSEMBLY OVERVIEW
• TRANSMISSION-SIDE SEALING FLANGE
• DUAL MASS FLYWHEEL
• CRANKSHAFT BEARING SHELLS ALLOCATION
• CRANKSHAFT, MEASURING AXIAL PLAY
• CRANKSHAFT, MEASURING RADIAL PLAY
• CRANKSHAFT DIMENSIONS
• SENSOR WHEEL
• CONNECTING ROD, SEPARATING NEW
• PISTONS
• PISTONS AND CYLINDER BORE, CHECKING
• CONNECTING ROD RADIAL CLEARANCE, MEASURING