2.0L - Crankshaft, Cylinder Block - Engine Code(s): Bpy: Overview Audi A3 8P facelift

RIBBED BELT AND ASSEMBLY BRACKET OVERVIEW

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions. When installing, make sure the belt is correctly seated in the belt pulley.

Scheme 267

1. Belt Pulley For the ribbed belt Removing and installing, refer to «VIBRATION DAMPER»(ref-496100-S30632073842012082100000)
2. Special Bolt Replace 20 Nm plus an additional 90° turn
3. Bolt 23 Nm
4. Ribbed Belt Tensioning Damper To release tension on ribbed belt, pivot using open-end wrench. Secure tensioner with special tool locking pin T10060A
5. Bracket for Assemblies Removing and installing, refer to «ACCESSORY ASSEMBLY BRACKET»(ref-496100-S13474777672012082100000)
6. Bolt 23 Nm
7. Bolt 23 Nm
8. Generator Removing and installing, refer to «REMOVAL AND INSTALLATION»(ref-496019-S38826765832012082100000) Moving the threaded bushings on the generator slightly to the rear will make is easier to install the generator.
9. Bolt Insert with locking fluid Locking fluid Follow the tightening sequence, refer to «ACCESSORY ASSEMBLY BRACKET»(ref-496100-S13474777672012082100000)
10. Bushing 2 pieces
11. Bolt 25 Nm
12. Air Conditioner (A/C) Compressor Removing and installing. Refer to «Removal and Installation»(ref-496031-S29258693212012082100000)
13. Ribbed Belt Ribbed belt routing (Scheme 268)Check for wear Do not kink Removing and installing, refer to «RIBBED BELT»(ref-496100-S16261009972012082100000)

Scheme 268

Scheme 269

Install bolts -1 through 6- and tighten by hand.

Tighten bolts -1 through 6- to 40 Nm.

Scheme 270

1. Bolt Replace 90 Nm plus an additional 90° turn Do not oil Fastening counter support 3415 (Scheme 272)
2. Crankshaft Toothed Belt Sprocket There must be no oil on the contact surface between the toothed belt sprocket and crankshaft Only possible to install in one position
3. Bolt Tightening sequence (Scheme 271)
4. Seal Removing and installing, refer to «CRANKSHAFT SEAL»(ref-496100-S22696513492012082100000). Do not oil
5. Sealing Flange, Front Must sit on alignment pins Removing and installing, refer to «FRONT SEALING FLANGE»(ref-496100-S38917956182012082100000)
6. Alignment Pins
7. Toothed Belt Gear Diamond Disc Replace after removing toothed belt gear
8. Bolt Tightening sequence (Scheme 271)
9. Cylinder Block Crankshaft, removing and installing, refer to «CRANKSHAFT OVERVIEW»(ref-496100-S07121912682012082100000) Piston and connecting rod, disassembling and assembling, refer to «PISTONS AND CONNECTING ROD OVERVIEW»(ref-496100-S34541659352012082100000)

Scheme 271

Install bolts -1 to 10- and tighten by hand.

Tighten the bolts -1 to 6- in a diagonal sequence in stages to 15 Nm.

Tighten bolts -7 to 10- to 15 Nm.

Scheme 272

REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL OVERVIEW

Note. Servicing clutch, refer to DESCRIPTION AND OPERATION .

Scheme 273

1. Bolt Replace 60 Nm plus additional 90° turn For dual-mass flywheel/drive plate
2. Dual Mass Flywheel Dual mass flywheel, removing and installing, refer to «DUAL MASS FLYWHEEL»(ref-496100-S32196127442012082100000). Only possible to install in one position - Bores are offset
3. Intermediate Plate Must be located on dowel sleeves Be careful not to damage or bend when installing Is hooked in at sealing flange (Scheme 275)
4. Bolt Tightening sequence (Scheme 274)
5. Sealing Flange with Rear Seal Always replace as a complete unit To install, use provided guide sleeve Removing and installing, refer to «REAR SEALING FLANGE»(ref-496100-S22846761712012082100000) Do not oil or grease the sealing lip of seal Wipe off any oil on the crankshaft bearing pin with a clean cloth before installing. Guide sleeve may only be removed after the sealing flange has been slid onto the crankshaft pin.
6. Fitting Pin
7. Bolt Tightening sequence (Scheme 274)
8. Cylinder Block Crankshaft, removing and installing, refer to «CRANKSHAFT OVERVIEW»(ref-496100-S07121912682012082100000) Piston and connecting rod, disassembling and assembling, refer to «PISTONS AND CONNECTING ROD OVERVIEW»(ref-496100-S34541659352012082100000)

Scheme 274

Install bolts -1 to 8- and tighten by hand.

Tighten the bolts -1 to 6- in a diagonal sequence in stages to 15 Nm.

Tighten bolts -7 to 8- to 15 Nm.

Scheme 275

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 276

1. Bolt 65 Nm plus an additional 90° turn
2. Bearing Cap Bearing cap 1: Belt pulley side Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
3. Bolt Replace 10 Nm plus an additional 90° turn Replace sensor wheel every time bolts are loosened (Scheme 277)
4. Needle Bearing For vehicles with manual transmission Pulling out and driving in, refer to «NEEDLE BEARINGS FROM CRANKSHAFT»(ref-496100-S04355669892012082100000)
5. Sensor Wheel For engine speed (RPM) sensor -G28- Only possible to install in one position - Bores are offset Replace sensor wheel every time bolts are loosened Removing and installing (Scheme 277)
6. Crankshaft Axial play new: 0.07 to 0.23 mm; Wear limit: 0.30 mm Check radial clearance with Plastigage 0.017 to 0.037 mm, Wear limit: 0.15 mm Do not turn crankshaft when measuring radial play Crankshaft dimensions, refer to «CRANKSHAFT DIMENSIONS»(ref-496100-S03593048662012082100000)
7. Thrust Washers For bearing 3
8. Bearing Shell for Cylinder Block With lubricating groove Do not interchange used bearing shells (mark) Classification for replacement part ordering, refer to «NEEDLE BEARINGS FROM CRANKSHAFT»(ref-496100-S04355669892012082100000)
9. Chain Sprocket For chain for oil pump Removing and installing, refer to «CHAIN SPROCKET»(ref-496100-S23395437572012082100000)
10. Bearing Shell Without lubricating groove Do not interchange used bearing shells (mark) The crankshaft bearing shells in the bearing caps are only available as a replacement part with a "yellow" color marking.

Scheme 277

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

Note. After tightening a second time, the attachment point of the countersunk screws of the sensor wheel are so deformed that the screw 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 OVERVIEW»(ref-496100-S07121912682012082100000)

Scheme 278

Note. Arrow points in direction of travel.

From the factory, the upper bearing shells are allocated to the cylinder block with the correct thickness. Colored spots serve to identify the bearing thicknesses.

The letters marked on the lower sealing surface of the cylinder block identify which bearing thickness must be installed in which location.

Note. If color markings can no longer be read, use the blue bearing shell. The lower crankshaft bearing shells are always shipped as replacement part with "yellow" color marking.

Scheme 279

1. Connecting Rod Bolt Replace 30 Nm plus an additional 90° turn 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. Pressure Relief Valve 27 Nm Opening pressure 1.6 to 1.9 bar
3. Oil Spray Jet For piston cooling
4. 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. Affiliation to the cylinder mark -B- Installation position: Markings -A- point to belt pulley side
5. Bearing Shells Upper bearing shell with oil hole for piston pin lubrication Installed location (Scheme 284)Do not interchange used bearing shells (mark) Axial play new: 0.10 to 0.30 mm; Wear limit: 0.40 mm Measure radial clearance with Plastigage: New: 0.02 to 0.06 m; Wear limit: 0.09 mm. Do not turn crankshaft when checking radial clearance
6. Connecting Rod Only replace as set Affiliation to the cylinder mark -B- Installation position: Markings -A- point to belt pulley side With oil hole for piston pin lubrication
7. Circlip
8. Piston Pin If difficult to move, heat piston to approximately 60 °C (140 °F) Removing and installing using a pilot drift VW 222 A
9. Piston Checking (Scheme 282)Mark installed position and cylinder allocation Arrow on piston face points toward belt pulley side Install with piston ring compressor For the correct piston and cylinder dimensions, refer to «PISTON AND CYLINDER DIMENSIONS»(ref-496100-S39608461592012082100000) Cylinder bore, checking (Scheme 283)
10. Piston Rings Offset gaps by 120° Use piston ring pliers for removing and installing "TOP" mark must face up toward piston crown Checking ring gap (Scheme 280)Check piston ring groove clearance (Scheme 281)

Scheme 280

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

Scheme 281

Clean the ring groove of piston before checking.

Scheme 282

Measure pistons approximately 10 mm from bottom edge and at points offset by 90° to piston pin axis.

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

Scheme 283

Special tools and workshop equipment required

1. Internal dial gauge 50 to 100 mm.
2. Inside Micrometer Set 18-100 mm US 1033/S

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

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

Scheme 284

Bearing shell -1- with connecting rod oil bore -arrow-.

Bearing shell -2- without connected rod cover oil bore.

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

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