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

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 289

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»(ref-496101-S18766598522012082100000)
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»(ref-496101-S18766598522012082100000) Axial clearance, refer to «CRANKSHAFT, MEASURING AXIAL PLAY»(ref-496101-S01815592772012082100000) Radial clearance, refer to «CRANKSHAFT, MEASURING RADIAL PLAY»(ref-496101-S24907391192012082100000) Do not turn crankshaft when measuring radial play Crankshaft dimensions, refer to «CRANKSHAFT DIMENSIONS»(ref-496101-S08688802482012082100000)
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»(ref-496101-S18766598522012082100000)
5. Bolt Replace Tightening order «CRANKSHAFT ASSEMBLY OVERVIEW»(ref-496101-S26078144502012082100000)
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»(ref-496101-S09672692512012082100000)
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»(ref-496101-S09672692512012082100000)
9. Thrust Washers For bearing 3
10. Bolt Replace Tightening order «CRANKSHAFT ASSEMBLY OVERVIEW»(ref-496101-S26078144502012082100000)

Scheme 290

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 291

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»(ref-496101-S24713266992012082100000)
3. Bearing Shells Installed position, refer to «PISTONS AND CONNECTING ROD ASSEMBLY OVERVIEW»(ref-496101-S12743997242012082100000) 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»(ref-496101-S24629073982012082100000) 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»(ref-496101-S27590641442012082100000)
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»(ref-496101-S27590641442012082100000) figure. Check piston ring groove clearance, refer to «PISTONS AND CYLINDER BORE, CHECKING»(ref-496101-S27590641442012082100000) 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»(ref-496101-S27590641442012082100000) 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»(ref-496101-S24713266992012082100000) Radial clearance, measuring, refer to «CONNECTING ROD RADIAL CLEARANCE, MEASURING»(ref-496101-S28456575412012082100000)

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 292

Scheme 293

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

Scheme 294

Clean the piston ring groove before checking.

Scheme 295

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 296

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.