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3.2l - Crankshaft, Cylinder Block - Engine Code(s): Bub & Cbra Audi A3 8P рестайлинг

Mechanical 52 illustrations ~3479 words

Scheme 215

Scheme 215: RIBBED BELT DRIVE COMPONENT OVERVIEW
  1. Ribbed Belt Check for wear Do not kink Before removing, mark direction of rotation using chalk or felt-tip marker. Reversing the running direction on a used belt can destroy it. Removal and installation, refer to «RIBBED BELT»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__ribbed-belt) When installing, make sure it is seated correctly on the pulleys
  2. Vibration Damper With ribbed belt pulley Removal and installation, refer to «VIBRATION DAMPER»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__vibration-damper)
  3. Bolt Replace 100 Nm plus an additional 180° turn Use counter-holder tool T10069 to loosen and tighten
  4. Bolt 20 Nm
  5. Ribbed Belt Pulley for Coolant Pump
  6. 8 Nm
  7. Bolt 50 Nm
  8. Tensioning Device for Ribbed Belt To release tension on ribbed belt, swing using open-end wrench. Secure with mandrel T10060 A Removal and installation, refer to «RIBBED BELT TENSIONER»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__ribbed-belt-tensioner)
  9. Coolant Pump Removal and installation, refer to «COOLANT PUMP»(/audi/a3/8p-2004-2008/remont/cooling-fan/#32l-cooling-system-engine-codes-bub-cbra__coolant-pump)
  10. Bracket for Assemblies Removal and installation, refer to «ACCESSORY ASSEMBLY BRACKET»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__accessory-assembly-bracket)
  11. Bolt 23 Nm
  12. Generator Removal and installation, refer to, refer to «REMOVAL AND INSTALLATION»(/audi/a3/8p-2004-2008/remont/charging-system/#battery-starter-generator-cruise-control)
  13. Bolt 3 pieces Tightening specifications and tightening sequence (Scheme 216)
  14. A/C Compressor Fitting Sleeve
  15. A/C Compressor Do not remove or disconnect refrigerant lines Removal and installation, refer to «Removal and Installation»(/audi/a3/8p-2004-2008/remont/automatic-hvac-system/#air-conditioning)
  16. 25 Nm
  17. Fitting Bolt 2 pieces Tightening specifications and tightening sequence (Scheme 216)
  18. Idler roller
  19. Bolt 40 Nm

Scheme 216

Scheme 216

Tighten bolts in 2 stages in -1 to 5- sequence as follows

Tighten bolts by hand.-- Tighten the bolts to 23 Nm.

DUAL-MASS FLYWHEEL COMPONENT OVERVIEW

Note. When working on the engine, secure the engine to the engine and transmission support. Refer to ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER .

Note. Items -4 through 23-, refer to TIMING CHAIN COVERS ASSEMBLY OVERVIEW .

Scheme 217

Scheme 217: DUAL-MASS FLYWHEEL COMPONENT OVERVIEW
  1. 60 Nm plus an additional 90° turn Replace
  2. Dual Mass Flywheel Removal and installation, refer to «DUAL MASS FLYWHEEL»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__dual-mass-flywheel)
  3. Seal Replacing, refer to «CRANKSHAFT SEAL, REPLACING»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__crankshaft-seal-replacing) .

CRANKSHAFT COMPONENT OVERVIEW

Note. When working on the engine, secure the engine to the engine and transmission support. Refer to ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER . If a large amount of metal shavings or particles were found when performing engine repairs, these could indicate crankshaft or rod bearings are damaged. To prevent further damage, the following steps must be carried out after the repair: Oil channels must be cleaned carefully; replace oil spray jets, oil cooler and oil filter.

Scheme 218

Scheme 218: CRANKSHAFT COMPONENT OVERVIEW
  1. Cylinder block Cylinder bore, checking (Scheme 225)Piston and cylinder dimensions, refer to «PISTON AND CYLINDER DIMENSIONS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__piston-and-cylinder-dimensions)
  2. Oil Spray Jet for Piston Cooling For crankshaft bearing 2 to 7 Opening pressure 2.0 bar pressure Removal and installation (Scheme 220)
  3. Bearing Shell For cylinder block with oil inlet bore Do not interchange used bearing shells (mark) Replacement parts are only color coded "yellow"
  4. Crankshaft After removal, lay aside so that sensor wheel item -10- is not rested on and becomes damaged Axial play new: 0.07 to 0.23 mm; wear limit: 0.30 mm Measure radial clearance with Plastigage Do not turn crankshaft when measuring radial play Radial clearance, new: 0.02 to 0.06 mm; wear limit: 0.10 mm Crankshaft dimensions, refer to «CRANKSHAFT DIMENSIONS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__crankshaft-dimensions) Timing chain wheel built into crankshaft
  5. Thrust washer For bearing 5 Observe locating point Lubricating groove faces crankshaft
  6. Bearing Cap Bearing cap 1: Belt pulley side Bearing cap 5 with notches for thrust washers Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
  7. 30 Nm plus an additional 180° ( 1 / 2 turn) Replace
  8. Bearing Shell For bearing cap without oil groove Do not interchange used bearing shells (mark) Replacement parts are only color coded "yellow"
  9. Thrust Washer For bearing 5 Observe locating point Lubricating groove faces crankshaft
  10. Sensor Wheel For Engine Speed (RPM) Sensor -G28- Replace sensor wheel every time bolts are loosened Installing (Scheme 219)
  11. 10 Nm plus an additional 90° ( 1 / 4 turn) Replace Replace sensor wheel every time bolts are loosened (Scheme 219)

Scheme 219

Scheme 219

Replace bolts and sensor wheel every time bolts are loosened.

Clean the contact surface of the crankshaft/sensor wheel; must be free of oil and grease.

Lightly coat the contact surface of the crankshaft/sensor wheel with locking adhesive; Locking adhesive.

Installation position

  1. The mark "VR6" -2- must be positioned at the bore of bolt -3-, that goes into the crank pin of the crankshaft (the contour of the crankshaft is shown by the dashed line -1-).
  2. The gap -arrow- in the ring gear lies across from the designation.
  3. The second "VR6" -4- is to be ignored.

Lightly fasten all new bolts by hand.

Then tighten bolt -3-.

Finally tighten both remaining bolts.

Tightening Specifications

ComponentNm
Sensor Wheel to Crankshaft10 + 90° (1)
(1) 90° corresponds to a 1/4 turn
(1)90° corresponds to a 1/4 turn

Scheme 220

Scheme 220

Scheme 221

Scheme 221: PISTON AND CONNECTING ROD COMPONENT OVERVIEW
  1. Connecting rod bolt - 30 Nm plus an additional 90° Replace Lubricate threads and contact surface Use old bolt to measure radial play Tighten to 30 Nm to measure radial play, do not turn further
  2. Connecting Rod Bearing Cap Affiliation to the cylinder mark -B- Installation position: Markings -A- must align
  3. Bearing Shells Do not interchange used bearing shells (mark) Bearing shell retaining tabs must be firmly seated in the notches Installation position: Retaining tabs of both bearing shells lie on the same side of the connecting rod Axial play new: 0.05 to 0.31 mm; wear limit: 0.40 mm Measure radial clearance with Plastigage Do not turn crankshaft when measuring radial play Radial clearance, new: 0.02 to 0.07 mm; wear limit: 0.10 mm Replacement parts are color coded "yellow" for lower and "red" for upper
  4. Connecting Rod With oil hole for piston pin lubrication Only replace as set Affiliation to the cylinder mark -B- Installation position: Mark -A- faces toward the shallow side of the piston (the shallow side of the piston head faces the cylinder block center)
  5. Circlip
  6. Piston Pin If tight, heat piston to 60 °C / 140 °F Removing and installing using a drift VW 222 A
  7. Piston Checking (Scheme 224)Mark installed location to connecting rod and affiliation to cylinder Shallow side of piston head faces cylinder block center Piston and cylinder dimensions, refer to «PISTON AND CYLINDER DIMENSIONS»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__piston-and-cylinder-dimensions) Install using piston insertion funnel T10147 (Scheme 226)
  8. Piston Rings Compression rings Offset gaps by 120° Use piston ring pliers for removal and installation Mark "TOP" must face toward piston head Checking ring gap (Scheme 222)Check piston ring groove clearance (Scheme 223)
  9. Piston Ring Oil scraping ring 3-part Install upper steel ring so gap is offset by 120° to neighboring compression ring Offset all oil scraping ring component gaps to each other

Scheme 222

Scheme 222

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

Use a feeler gauge to measure.

Piston ring (dimensions in mm)NewWear limit
Compression ring0.20 to 0.401.00
Tapered ring0.20 to 0.401.00
Oil scraping ring0.25 to 0.501.00

Scheme 223

Scheme 223

Clean the ring groove of piston before checking.

Use a feeler gauge to measure.

Piston ring (dimensions in mm)NewWear limit
Compression ring0.04 to 0.090.15
Tapered ring0.03 to 0.060.15
Oil scraping ring0.02 to 0.060.15

Scheme 224

Scheme 224

Measure pistons approximately 6 mm from bottom edge and at points offset by 90° to piston pin axis.

Use external micrometer 75 to 100 mm to measure.

  1. Maximum deviation from nominal dimension: 0.04 mm.

Scheme 225

Scheme 225

Measure bores at 3 locations in both directions -A- across engine and -B- in line with crankshaft.

Use internal dial gauge 50 to 100 mm to measure.

  1. Maximum deviation from nominal dimension: 0.08 mm.

Scheme 226

Scheme 226

Note. If a new funnel is used, next guide pistons with oil piston rings through funnel twice and remove resulting metal shavings if necessary. Only then install piston with piston rings.

Push piston by hand into oiled piston installation tool.

  1. Flat side of piston crown must face toward funnel pin -arrow-.

Hold funnel (with piston inserted) on upper edge and press piston in with both thumbs.

Push piston in until it protrudes approximately 15 mm from lower edge of funnel.

Insert piston into appropriate cylinder bore.

  1. Funnel pin -arrow- must point toward center of cylinder block.

Press funnel tightly against cylinder block and push piston in.

CRANKSHAFT DIMENSIONS

Reconditioning dimension (dimensions in mm)Crankshaft bearing pins-diameterConnecting rod bearing pins-diameter
Basic dimension (1)59.958 to 59.97853.958 to 53.978
(1) Reworking is not permitted.
(1)Reworking is not permitted.

PISTON AND CYLINDER DIMENSIONS

Reconditioning dimension (dimensions in mm)Piston diameterCylinder bore diameter
Basic dimension83.96584.010

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
A/C Compressor25
Bearing Cap30 + 180° 1
Connecting Rod30 + 90° 1
Dual Mass Flywheel60 + 90° 1
Generator23
Idler roller40
Ribbed Belt Pulley for Coolant Pump20
Sensor Wheel to Crankshaft10 + 90° 1
Tensioning Device for Ribbed Belt50
Vibration damper100 + 180° 1
1 Always replace

Accessory assembly bracket tightening sequence

Tighten bolts in 2 stages in -1 to 5- sequence as follows

Tighten bolts by hand.-- Tighten the bolts to 23 Nm.

RIBBED BELT

Special tools and workshop equipment required

  1. Locking Pin T10060 A

Removing

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.

Scheme 227

Scheme 227

Remove the ribbed belt from the generator belt drive pulley.

Remove center noise insulation fasteners -1 to 3-.

Scheme 228

Scheme 228

Remove right noise insulation fasteners -1 to 3-.

Scheme 229

Scheme 229

Remove ribbed belt from remaining belt pulleys.

Installing

Installation is in reverse order of removal, note the following

Note. All components (generator, A/C compressor) must be installed securely before installing ribbed belt.

Route ribbed belt as follows

Scheme 230

Scheme 230
  1. Idler roller
  2. Vibration damper
  3. Coolant pump
  4. Tensioning roller
  5. Generator
  6. Idler roller
  7. A/C Compressor

Hold tensioner with open end wrench, remove T10060 A or angled hex socket head wrench and release tensioner.

Check ribbed belt for proper seating.

Start engine and check belt running.

RIBBED BELT TENSIONER

Removing

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.

Note. The tensioner is not locked.

Remove bolt -arrow- and remove ribbed belt tensioner.

Scheme 231

Scheme 231

Installing

  1. Tightening specifications, refer to «RIBBED BELT DRIVE COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra)

Installation is in reverse order of removal, note the following

Install ribbed belt. Refer to RIBBED BELT .

ACCESSORY ASSEMBLY BRACKET

Special tools and workshop equipment required

  1. Locking Pin T10060 A

Removing

Note. All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

CAUTIONObserve safety precautions when disconnecting the battery. Refer to REMOVAL AND INSTALLATION .

Remove tool formed insert under luggage compartment floor covering.

Remove cover -arrow- for battery compartment

Scheme 232

Scheme 232

Remove formed insert from over the battery.

With ignition switched off, disconnect Battery Ground (GND) cable -arrow-.

Scheme 233

Scheme 233

Remove center noise insulation fasteners -1 to 3-.

Remove right noise insulation fasteners -1 to 3-.

Disconnect secondary air hose at position indicated by -arrow-.

Scheme 234

Scheme 234

Free up air hose to Secondary Air Injection (AIR) pump.

Remove top mounting bolts for fan shroud -top arrows-.

Scheme 235

Scheme 235

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.

Remove ribbed belt.

Free up coolant hose at bottom on fan shroud.

Scheme 236

Scheme 236

Disconnect electrical connector -3- at secondary air injection (AIR) pump motor -V101- and free up electrical wiring.

On vehicles with DSG transmission, remove coolant pipe bracket -2- to transmission oil cooler.

Remove bolts -1-.

Loosen bolt -4- and remove Secondary Air Injection (AIR) pump with bracket.

Disconnect electrical harness connectors -1- for coolant fans at bottom on fan shroud.

Remove mounting bolts for fan shroud at bottom -bottom arrows-.

Pull out fan shroud downward with both fans.

Disconnect electrical harness connector -1- for A/C clutch on A/C compressor and free up electrical wire.

Scheme 237

Scheme 237
WARNINGThe air conditioning refrigerant circuit must not be opened.

Remove bolts -arrow- for A/C compressor.

Securely tie the A/C compressor with connected coolant hoses at front on the longitudinal member.

Remove electrical wire -1- on generator.

Scheme 238

Scheme 238

Separate the electrical connector -2-.

Note. Ignore -3-.

Remove upper idler roller -1-.

Scheme 239

Scheme 239

Remove mounting bolts -2- and -3- for generator.

Note. Generator can be removed from bracket only with the upper mounting bolt still installed.

Remove generator from accessory assembly bracket.

Remove generator downward and to the left.

Disconnect electrical connector -3- at after-run coolant pump -V51- -2- and remove pump with coolant hoses -1- and -4- connected downward from rubber loops on bracket. Spray rubber loops with silicone-free lubricant, if necessary.

Scheme 240

Scheme 240

Remove bolts -1 to 5- and remove accessory assembly bracket.

Note. Disregard -arrow-.

Installing

  1. Tightening specifications, refer to «RIBBED BELT DRIVE COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra)

Installation is in reverse order of removal, note the following

Note. Bolts -1- and -2- are fitting bolts.

Next, hand tighten the bolts in sequence -1 to 5-.

Then tighten bolts in sequence -1 to 5-.

To make it easier to install the generator, drive the bushings for the retaining bolts back slightly.

Install generator. Refer to REMOVAL AND INSTALLATION .

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

Install ribbed belt. Refer to RIBBED BELT .

VIBRATION DAMPER

Special tools and workshop equipment required

  1. Locking Pin T10060 A
  2. Counter-Holder Tool T10069

Removing

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.

Remove center noise insulation fasteners -1 to 3-.

Remove right noise insulation fasteners -1 to 3-.

Remove the ribbed belt from the vibration damper belt drive pulley.

Remove bolt from vibration damper, thereby using T10069 to counter-hold.

Scheme 241

Scheme 241

Installing

  1. Tightening specifications, refer to «RIBBED BELT DRIVE COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra)

Installation is in reverse order of removal, note the following

Use new bolt to fasten.

To fasten the bolt for vibration damper, counter-hold with T10069.

Install ribbed belt. Refer to RIBBED BELT .

CRANK SHAFT SEALING RING, BELT PULLEY SIDE, VEHICLES UP TO 11.2004

Special tools and workshop equipment required

  1. Seal Remover 3203
  2. Seal Installer 3266
  3. Assembly Tool T10053
  4. Locking Pin T10060 A
  5. Counter-Holder Tool T10069

Procedure

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.

Remove center noise insulation fasteners -1 to 3-.

Remove right noise insulation fasteners -1 to 3-.

Remove the ribbed belt from the vibration damper belt drive pulley.

Remove bolt from vibration damper, thereby using T10069 to counter-hold.

Turn inner portion of 3203 3 turns (approximately 4 mm) out from the outer portion and lock position with knurled thumb screw.

Scheme 242

Scheme 242

Lubricate the threaded head of the seal remover, place against seal, and with strong force screw into the seal as far as possible.

Loosen knurled thumb screw and turn inner portion against crankshaft until the seal is pulled out.

Secure the seal remover in a vise at the flat spots. Remove seal using pliers

Clean the running and sealing surfaces.

Note. Do not lubricate seal prior to installation.

Place T10053/1 on crankshaft pin.

Scheme 243

Scheme 243

Carefully push the seal over the guide sleeve and as far onto the end of the crankshaft as possible.

Remove the guide sleeve.

Press seal in against stop using old vibration damper screw -1- and 3266.

Scheme 244

Scheme 244

Install vibration damper with new bolt. Refer to VIBRATION DAMPER .

Install ribbed belt. Refer to RIBBED BELT .

SEALING FLANGE, BELT PULLEY SIDE

Special tools and workshop equipment required

  1. Locking Pin T10060 A
  2. Counter-Holder Tool T10069
  3. Assembly Tool T10215 for vehicles from 11.2005
  4. Hand drill with plastic brush attachment
  5. Protective eyewear

Removing

  1. Engine installed.

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.

Remove center noise insulation fasteners -1 to 3-.

Remove right noise insulation fasteners -1 to 3-.

Remove the ribbed belt from the vibration damper belt drive pulley.

Remove bolt from vibration damper, thereby using T10069 to counter-hold.

Remove bolts -1 to 11-.

Scheme 245

Scheme 245

Pry off and remove front sealing flange.

Drive out the seal from the removed flange.

Installing

  1. Tightening specifications, refer to «RIBBED BELT DRIVE COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra)

Installation is in the reverse order of removal, note the following

Note. Place a rag over open section of oil pan.

Carefully remove any sealant residue from the cylinder block and oil pan.

WARNINGRisk of eye injury. Wear safety glasses.

Remove sealant residue from sealing flange for example with a rotating plastic brush.

Scheme 246

Scheme 246

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

Cut tube nozzle at front marking (nozzle dia. approximately 3 mm).

Scheme 247

Scheme 247

Apply a thin bead of sealant to the edge between cylinder block and oil pan -arrow-.

Scheme 248

Scheme 248

Lightly coat the lower sealing surface of the sealing flange with sealant -shaded area-.

Scheme 249

Scheme 249

Apply a thin bead of sealant -arrow- to the clean sealing surface of the sealing flange, as shown in the illustration.

Scheme 250

Scheme 250
  1. Thickness of sealant bead -arrow- : 2 to 3 mm.

Note. The sealant bead may not be thicker than 3 mm, otherwise excess sealant could enter the oil pan and clog the oil intake tube. The sealing flange must be installed within 5 minutes of being applied with sealant.

Vehicles through 11.2004

Carefully slide sealing flange onto reamed bolt at cylinder block.

Note. To install the sealing flange with installed seal, use the T10053/1.

Vehicles from 11.2004

Carefully slide sealing flange onto guide pins -arrows- on cylinder block using T10215.

Scheme 251

Scheme 251

All Vehicles

Tighten bolts in 3 stages as follows

Install bolts -1 to 11- and tighten by hand.-- Tighten the bolts -1 to 6- diagonally in stages to 10 Nm.-- Tighten bolts -7 to 11- to 10 Nm.

Vehicles through 11.2004

Install the crankshaft seal belt pulley side. Refer to CRANK SHAFT SEALING RING, BELT PULLEY SIDE, VEHICLES UP TO 11.2004 .

All Vehicles

Install vibration damper with new bolt. Refer to VIBRATION DAMPER .

Install ribbed belt. Refer to RIBBED BELT .

DUAL MASS FLYWHEEL

Note. When working on the engine, secure the engine to the engine and transmission support. Refer to ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER .

Special tools and workshop equipment required

  1. Counter-Holder Tool T10069

Removing

  1. Transmission removed.

Mark dual-mass flywheel to engine.

Note. To prevent damage to dual-mass flywheel when removing, bolts -B- must not be removed using an air-powered or impact wrench. Only removing bolts by hand is permitted.

Rotate dual-mass flywheel -A- so that bolts stand centered to holes -arrows-.

When removing bolts, make sure that no bolt head makes contact on dual-mass flywheel because it will otherwise be damaged when further screwing the bolt.

Remove dual-mass flywheel while counter holding vibration damper with T10069.

Installing

  1. Tightening specifications, refer to «DUAL-MASS FLYWHEEL COMPONENT OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-bub-cbra__dual-mass-flywheel-component-overview)

Installation is in the reverse order of removal, note the following

Secure with new bolts.

NEEDLE BEARING IN CRANKSHAFT

Special tools and workshop equipment required

  1. Drift VW 207 C or Centering Mandrel 3176
  2. Internal Puller Kukko 21/1
  3. Counter-Support Kukko 22/1
  4. Depth gauge

Removing

  1. Transmission removed.

Pull out needle bearing using Kukko 21/1 and Kukko 22/1.

Scheme 252

Scheme 252

Installing

Drive in needle bearing using VW 207 C or 3176.

Scheme 253

Scheme 253
  1. Side of needle bearing with writing on it must be readable when installed.

Needle bearing location

Scheme 254

Scheme 254
  1. Dimension -a- = 2.0 mm.

CRANKSHAFT SEAL, REPLACING

Special tools and workshop equipment required

  1. Assembly Tool T10122
  2. Pulling Hook T20143/2

Procedure

  1. Transmission removed.

Remove the dual-mass flywheel. Refer to DUAL MASS FLYWHEEL .

Pry out sealing ring using T20143/2.

Scheme 255

Scheme 255

Clean the running and sealing surfaces.

Note. Do not lubricate seal prior to installation.

Slide new seal -A- over T10122/1 onto T10122/2.

Scheme 256

Scheme 256
  1. Installation position: Closed side faces toward fitting sleeve.

Disconnect both sleeves.

Position T10122/2 with seal on crankshaft.

Scheme 257

Scheme 257

Press seal in evenly all around using T10122/3 until flush.

Scheme 258

Scheme 258

Further installation is in reverse order of removal, note the following

Install dual-mass flywheel. Refer to DUAL MASS FLYWHEEL .

Scheme 259

Scheme 259: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Seal Remover 3203
  2. Seal Installer 3266
  3. Assembly Tool T10053
  4. Locking Pin T10060 A
  5. Counter-Holder Tool T10069

Special tools and workshop equipment required

Scheme 260

Scheme 260

Scheme 261

Scheme 261

Scheme 262

Scheme 262

Scheme 263

Scheme 263

Scheme 264

Scheme 264

Scheme 265

Scheme 265

Scheme 266

Scheme 266
  1. Locking Pin T10060 A
  2. Counter-Holder Tool T10069
  3. Assembly Tool T10215 for vehicles from 11.2005
  4. Drift VW 207 C or Centering Mandrel 3176
  5. 1 - Internal Puller Kukko 21/1
  6. 4 - Counter-Support Kukko 22/1
  7. Assembly Tool T10122
  8. Pulling Hook T20143/2