2.8L V6 30V (Engine Code: Aha, Atq): Other Audi A4 B5 facelift

ACCELERATOR PEDAL

1. Remove clip for accelerator pedal cable on throttle body. Depress and hold accelerator pedal to Wide Open Throttle (WOT) position.
2. On manual transmission vehicles, reinstall clip for accelerator pedal cable. On automatic transmission vehicles, disconnect kickdown switch 2-pin harness connector. Using DVOM, ensure continuity exists between kickdown switch terminals in WOT position. On all models, release accelerator pedal. Adjustment is complete. After adjusting accelerator pedal, check Closed Throttle Position (CTP) switch and WOT stops.

FUEL PRESSURE RELEASE

Note. For more information on relay identification, see appropriate COMPONENT LOCATIONS article in ELECTRICAL section.

Remove fuel pump fuse No. 28. from fuse/relay block, under left side of instrument panel. (Scheme 195) Start engine. Allow engine to run until it stops. Turn ignition off. Disconnect negative battery cable. Install fuel pump relay. Slight pressure may remain in system. Before disconnecting any fuel system line, cover connector with a clean shop towel.

Scheme 195

COOLING SYSTEM BLEEDING

Scheme 196

1. Expose vent hole on heater pipe, at firewall connection, by pulling back heater hose. (Scheme 196) Fill cooling system through expansion tank until coolant comes out of vent hole. Tighten heater hose.
2. Fill expansion tank to proper level. Loosen bleeder screw on lower coolant hose, located under expansion tank. Unbolt expansion tank if necessary. Top off coolant until it flows from bleed screw. Close bleed screw.
3. Fill expansion tank to proper level. Loosen bleed screw on front coolant line between power steering pump and left of cylinder head. Top off coolant until it flows from bleed screw. Close bleed screw.
4. Fill expansion tank to proper level. Install expansion tank cap. Start engine and raise engine speed to 2000 RPM for about 5 minutes. Return engine to idle. Check coolant level in expansion tank. Fill as necessary.

A6

1. Inspect coolant lines for bleed screws. One is located at front of engine near the upper hose connection. Loosen bleed screws front and on rear coolant pipe.
2. Expose vent hole on heater pipe at firewall connection by pulling back heater hose. (Scheme 196) Fill cooling system through expansion tank until coolant comes out of vent hole and bleed screws. Tighten heater hose and bleed screws.
3. Fill expansion tank to proper level. Install expansion tank cap. Adjust heater controls to maximum heat position. Start engine and raise engine speed to 2000 RPM for about 3 minutes. Ensure cooling fan operates. Return engine to idle. Check coolant level in expansion tank. Fill as necessary. Repeat and recheck.

LOCK CARRIER

Note. Lock carrier is slid forward onto alignment tools. This will allow servicing of front engine components. Lock carrier can be removed at technicians discretion.

Placing In Service Position (A4 & A6)

Note. It is not necessary to completely removal noise insulation from beneath the engine. Only remove the quick release fasteners the attach to the front bumper assembly.

Scheme 197

Scheme 198

Scheme 199

1. Remove front bumper. See «FRONT BUMPER»(ref-147486-S21797918242002091600000).
2. Unbolt air guide between lock carrier and air filter on lock carrier. Inspect headlight and turn signal electrical connectors and wiring harness (which may hang up when lock carrier is moved forward).
3. On right side, remove bolt (5) and install support tool (3369) in its place. (Scheme 197)and (Scheme 198).
4. On left side, install support tool (3369) in threaded hole in chassis. (Scheme 199)
5. Remove on both sides, all (No. 2) bolts. (Scheme 197)
6. Remove on both sides, all (No. 3 and 4) bolts. (Scheme 197) Slide lock carrier forward unit the rear bolt hole in lock carrier aligns with the forward threaded fender bolt hole.
7. Secure lock carrier in this position, by placing fender bolts in holes. (Scheme 200) To install, reverse placing in service position procedure.

Scheme 200

INTAKE MANIFOLD

Note. Obtain radio code before disconnecting battery.

Note. Always replace seals, gaskets and O-rings.

CYLINDER HEAD

Note. Engine must be cool before proceeding with cylinder head removal. DO NOT position pistons at TDC during removal procedure.

Scheme 201

1. On A4 and A6 models, remove front bumper. See «FRONT BUMPER»(ref-147486-S21797918242002091600000). Place lock carrier into service position. See «LOCK CARRIER»(ref-147486-S40535456302002091600000).
2. On all models, remove trim cover from top of engine. Remove noise insulation panel from under engine. see scheme 8
3. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-147486-S17694092262002091600000). Obtain radio anti-theft code (if equipped), and disconnect negative battery cable.
4. Drain coolant from radiator. Remove coolant drain plug from engine. See «DRAINING COOLING SYSTEM»(ref-147486-S06159856372002091600000). Remove air intake hose with MAF sensor and throttle valve control module. Disconnect accelerator pedal cable.
5. Noting installed position for reassembly reference, disconnect all necessary electrical and vacuum connections to facilitate cylinder head removal. Remove intake manifold securing plate at rear of manifold.
6. Remove serpentine drive belt. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(ref-147486-S28133037962002121900000).
7. Remove timing belt from camshaft sprockets. See «TIMING BELT»(ref-147486-S11057228442002091600000). It is not necessary to completely remove timing belt from crankshaft sprocket.
8. Disconnect exhaust pipes from cylinder heads. Unbolt exhaust system from transmission bracket. Disconnect fuel supply and return lines.
9. Remove fuel injector harness connectors from fuel injectors. Unbolt fuel rail from intake manifold. Remove fuel rail and injectors as an assembly.
10. Unbolt bracket for ignition coils and set aside. Remove intake manifold. Remove secondary air system connection pipe below intake manifold. Unbolt coolant pipe at rear of cylinder head.
11. On driver side cylinder head, remove camshaft sprocket using sprocket puller. (Scheme 213) Remove rear (inboard) timing belt from drive side cylinder head.
12. Unbolt coolant pipe at front of cylinder head. Remove cylinder head covers. Remove cylinder head bolts in REVERSE order of installation tightening sequence. (Scheme 207)

CORE PLUG (CYLINDER HEAD)

CRANKSHAFT FRONT OIL SEAL

Note. During this procedure. No. 1. piston must be placed at Top Dead Center (TDC).

Scheme 202

Scheme 203

1. Remove sealing plug from hole in left side of cylinder block. Position crankshaft to Top Dead Center (TDC) for cylinder No. 1. Ensure TDC hole can be seen or felt through sealing plug hole. Install Crankshaft Holder (3242) into sealing plug hole to prevent crankshaft from rotating. (Scheme 209)
2. Remove timing belt. See «TIMING BELT»(ref-147486-S11057228442002091600000).
3. Using Seal Remover (3203), remove crankshaft seal. Unscrew inner part of Oil Seal Extractor (3202) 2 turns (about 3 mm) out of outer part and lock with knurled screw. (Scheme 210)
4. Lubricate thread head of oil seal extractor, place it in position while applying firm pressure screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against crankshaft until oil seal has been extracted. (Scheme 210)

TIMING BELT

Note. Obtain radio code before disconnecting battery.

Note. For cylinder head removal. DO NOT position pistons at TDC during removal procedure.

Scheme 204

Scheme 205

1. For A4 and A6, move lock carrier into service position. See «LOCK CARRIER»(ref-147486-S40535456302002091600000).
2. Remove serpentine belt and viscous fan. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(ref-147486-S28133037962002121900000).
3. Remove noise insulation panel from under engine. see scheme 8 Remove trim cover from top of engine. see scheme 21
4. Rotate crankshaft using center bolt so that timing marks are aligned. (Scheme 212) Remove upper timing belt guards.
5. Check position of camshafts. Larger holes of camshaft securing plates (located on front of camshaft sprockets) must be on inside and must align. see scheme 54 If camshafts are in correct position, go to next step. If larger holes are positioned to the outside, rotate crankshaft one turn further. Go to next step.
6. Remove sealing plug from alignment access hole in left side of engine block. Ensure that hole in crankshaft is visible or be felt through alignment access hole. Install Crankshaft Holder (3242) into alignment access hole to prevent crankshaft from rotating. see scheme 55
7. Remove serpentine belt tensioner.
8. Remove center and right timing belt covers. If timing belt is to be reused, mark belt running direction with marker or crayon.
9. Using an 8-mm wrench, turn timing belt tensioning roller clockwise until tensioning lever compresses tensioner so that a pin (2 mm in diameter) can be inserted into plunger. see scheme 56 Insert pin and release tension.
10. Remove vibration damper bolts around center bolt. see scheme 57 Remove vibration damper. Remove serpentine belt idler pulley. Remove timing belt cover. Remove timing belt.

Scheme 206

Scheme 207

Scheme 208

1. Remove camshaft sprocket securing bolts and securing plates. Install a 10 mm bolt in center of camshaft. Install Sprocket Puller (3032) on camshaft sprocket. (Scheme 213) Remove camshaft sprockets.
2. Reinstall both camshaft sprockets, together with locking plate, and hand tighten bolts. Camshaft sprocket must be able to move on tapered camshaft. Repeat for each camshaft.
3. Install timing belt. (Scheme 214)
4. Install Camshaft Holding Bar (3391). (Scheme 215)
5. Use an 8-mm wrench to turn timing belt tensioning roller clockwise until tensioning lever compresses, and remove spring pin. see scheme 56
6. Using a torque wrench with an 8 mm hex bit, apply 11 ft. lbs. (15 N.m) to timing belt tensioner roller (pulley bearing). This ensures timing belt tensioner has expanded completely and properly tensioning belt.
7. Tighten camshaft sprockets to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000). To complete installation, reverse removal procedure.
8. Install serpentine belt and viscous fan. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(ref-147486-S28133037962002121900000). On A4 and A6, secure lock carrier to body. See «LOCK CARRIER»(ref-147486-S40535456302002091600000).

CAMSHAFTS

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 224)and (Scheme 225).

Scheme 209

Scheme 210

1. Remove timing belt. See «TIMING BELT»(ref-147486-S11057228442002091600000). Turn crankshaft back slightly (moves pistons off Top Dead Center TDC).
2. Remove camshaft drive sprocket bolt. Remove camshaft drive sprocket using puller. (Scheme 213)
3. Disconnect Camshaft Position (CMP) sensor housing and sensor rotor. Remove rear (inboard) timing belt guard. Remove valve cover.
4. Clean camshaft drive chain and chain sprockets. Moving only the camshafts, align the marks on the camshaft sprocket with arrows on the bearing caps. see scheme 61 Using paint, mark chain and sprockets opposite arrows on bearing caps. Distance between both arrows (and between paint markings) is 16 rollers on the chain.
5. Carefully compress camshaft adjuster using Chain Tensioner (3366). Tighten to keep slight pressure on chain between camshafts. DO NOT overtighten camshaft adjuster. see scheme 62
6. Unbolt camshaft adjuster. Remove the following bearing caps. see scheme 63 Evenly loosen bearing caps No. 1, 3, 5 and 7 alternately and diagonally. Identify each cap for installation in original position. No. 1 (Double Bearing Cap) No. 3 (Center Bearing Cap) No. 5 (Cap Located Behind Chain) No. 7 (Cap Next To Camshaft Adjuster)
7. Evenly loosen bearing caps No. 2 and No. 4 alternately and diagonally. Remove and place in correct order for reassembly in original position.
8. Remove camshafts together with camshaft adjuster. If reusing camshafts, inspect for wear. See «CAMSHAFT»(ref-147486-S07008103872002121200000) table under ENGINE SPECIFICATIONS.
9. To check camshaft axial (end) play, see «CYLINDER HEAD»(ref-147486-S14952743132002091600000) under OVERHAUL.

VALVE LIFTERS

Note. Valve lifters are not repairable or adjustable. Replace faulty lifters. Irregular valve train noise is normal when starting engine.

Scheme 211

1. Start engine and run until cooling fan cycles at least once. Increase engine speed to 2500 RPM for 2 minutes or test drive vehicle and observe valve train noise. If valve train noise is still considered noisy, go to next step.
2. Turn engine off. Remove valve cover. Rotate crankshaft until camshaft lobes point upward on lifter being checked. Using a wooden or plastic wedge, push down on top of lifter. (Scheme 216)
3. Try inserting a.008" (.20 mm) feeler gauge between top of lifter and camshaft. If feeler gauge fits between top of lifter and camshaft, replace faulty lifter.
4. If irregular valve noise occurs repeatedly on short trips and disappears after extended driving, oil check valve must be replaced. See «OIL CHECK VALVE REPLACEMENT»(ref-147486-S41499381502002091600000).

CAMSHAFT OIL SEALS

Note. For help in identifying components and component locations (Scheme 224)and (Scheme 225).

Note. Various oil seal configurations may be used, ensure proper seal application is used.

Scheme 212

1. Remove timing belt. See «TIMING BELT»(ref-147486-S11057228442002091600000).
2. Remove camshaft drive sprocket bolt. Remove camshaft drive sprocket.
3. Unscrew inner part of Oil Seal Extractor (3240) oil seal extractor 2 turns (about 3 mm) out of outer part and lock with knurled screw. (Scheme 217)
4. Lubricate thread head of Oil Seal Extractor (3240), place it in position while applying firm pressure screw it as far as into oil seal. Loosen knurled screw and turn inner part of extractor against camshaft until oil seal has been extracted.

DRIVE PLATE (A/T)

Note. The following procedure is given assuming the transmission has been removed or the engine has been removed for servicing.

Scheme 213

1. Holding drive plate stationary, remove drive plate bolts. Manufacturer requires using NEW drive plate bolts on installation.
2. BEFORE removing shims and drive plate, note installed position for reassembly reference. see scheme 70 Mark drive plate and shims for reference.
3. For vehicles equipped with an automatic transmission, inspect bushing at crankshaft flange. see scheme 72 See «BEARING BUSHING FOR TORQUE CONVERTER»(ref-147486-S22760830732002091600000).

Scheme 214

Scheme 215

1. Install drive plate and shims in original locations. Install OLD bolts into flange. Check dimension "A" at 3 evenly space points. Find average of readings. Specification should be approximately 12.3 mm (0.484". see scheme 71 If specification is not correct, different size shims are available from manufacturer to obtain correct clearance.
2. When correct shim size is installed, install NEW drive plate bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).
3. If installing new crankshaft or engine block, ensure torque converter bearing bushing is installed correctly. see scheme 72 See «BEARING BUSHING FOR TORQUE CONVERTER»(ref-147486-S22760830732002091600000).

CRANKSHAFT REAR OIL SEAL

Note. If possible, replace oil seal together with flange.

THERMOSTAT

Note. Obtain radio code before disconnecting battery.

Scheme 216

Scheme 217

1. Drain engine coolant. See «DRAINING COOLING SYSTEM»(ref-147486-S06159856372002091600000).
2. Remove complete front bumper assembly. See «FRONT BUMPER»(ref-147486-S21797918242002091600000). Place lock carrier in service position. See «LOCK CARRIER»(ref-147486-S40535456302002091600000).
3. Remove serpentine belt. See «SERPENTINE DRIVE BELT & VISCOUS COOLING FAN»(ref-147486-S28133037962002121900000).
4. Remove timing belt guard. Remove timing belt from camshaft sprockets. See «TIMING BELT»(ref-147486-S11057228442002091600000).
5. Remove thermostat housing bolts. Housing is located near front of passenger side cylinder head. see scheme 76and see scheme 77. Remove thermostat.
6. Lube new O-ring gasket with coolant. Install thermostat with bleeder valve at top (12 o'clock) position. Tighten thermostat housing bolts to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000). To complete installation, reverse removal procedure.
7. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-147486-S31613995762002091600000).

WATER PUMP

Note. Obtain radio code before disconnecting battery.

Note. Water pump is driven by the timing belt. Timing belt removal is required.

OIL PAN(A4 & A6)

Note. Obtain radio code before disconnecting battery. For help in identifying components and component locations, refer to illustrations (Scheme 228) - (Scheme 229).

Scheme 218

Scheme 219

1. Measure cylinder head warpage, measure at several points along gasket surface using straight edge and feeler gauge. (Scheme 231)
2. If warpage exceeds specification, machine cylinder head. See «CYLINDER HEAD»(ref-147486-S25493106472002091600000) table under ENGINE SPECIFICATIONS. If machining causes cylinder head height to be less than specification, replace cylinder head. When checking dimensions for cylinder head height, measure at (A) through the holes for the head bolts. see scheme 92

Camshaft Axial Play

Measure camshaft axial play with lifter and camshaft chain removed, and camshaft bearing caps No. 2. and No. 4. installed. see scheme 63 See CAMSHAFT table under ENGINE SPECIFICATIONS. see scheme 93

Scheme 220

Valves

Valves must not be refaced by grinding. Hand lap only. If lapping does not produce proper sealing, check valve seat. See VALVE SEAT .

Valve Guides Checking

Note. Intake valve stem diameter differs from exhaust valve stem diameter. Use intake valves in intake guides and exhaust valves in exhaust guides when measuring valve guide wear.

1. To measure valve guide wear, attach dial indicator to cylinder head. Insert valve into guide until valve stem tip is even with top end of guide.
2. Lightly push edge of valve head against dial indicator tip. Zero dial indicator. Push valve away from dial indicator, in direction opposite of camshaft axis.
3. Maximum allowable deflection is.032" (.8 mm) on intake or exhaust valve. see scheme 94 If deflection does not exceed specification, guide is okay. If deflection exceeds specification, recheck using new valve. If deflection still exceeds specification, replace worn guides.

Scheme 221

Valve Guide Installing

Note. When the shoulder on guide makes contact, the pressure must not exceed 10 kN (1.0 ton). Shoulder may break off if pressure is exceeded.

1. Coat new valves guides with clean oil. Using drift (3360) press into cold cylinder head from camshaft side. Stop when shoulder makes contact.
2. Ream guides out with hand reamer (3363), ensure plenty of cutting fluid is used.
3. Reface valve seats. See «VALVE SEAT»(ref-147486-S35384953362002091600000) .

Valve Seat

Note. When repairing engines with leaking valves, it is not sufficient to replace or renew valve seats and valves. It is also necessary to check the valve guides for wear. This is particularly important on high mileage engines. The valve seats should only be refaced just enough to produce a perfect seating pattern. The maximum permissible refacing dimension must be calculated before beginning refacing. If the refacing dimension is exceeded, the function of the hydraulic valve lifters can no longer be guaranteed and the cylinder head should be replaced. If the valve is to be replaced as part of a repair, use a new valve for the calculation.

1. Insert valve into guide. Press valve tightly against valve seat. Lay a straightedge across top of cylinder head. Measure distance between valve stem tip and bottom of straightedge. This is valve installed height. If a new valve is going to be installed, use new valve to make this measurement.
2. If valve stem height is less than 1.339" (34.0 mm) on intake valve (outer), 1.327" (33.7 mm) intake valve (center), or 1.354" (34.4 mm) on exhaust valve, install a new valve and measure again. see scheme 95
3. If valve stem height measurement is still less than specification, replace cylinder head. If valve stem height exceeds specification, seat can be machined; however, DO NOT machine enough material away from seat to cause valve stem height to be less than minimum specification.

Scheme 222

Scheme 223

1. Remove camshafts. See «CAMSHAFTS»(ref-147486-S28562019622002091600000) under REMOVAL & INSTALLATION.
2. Remove valve lifters and place them with contact surface downward. During removal make sure lifters are not interchanged.
3. Remove spark plugs with spark plug removal tool (3122B).
4. Set piston of relevant cylinder to Bottom Dead Center (BDC).
5. Screw VW pressure hose (653/3) into spark plug thread. see scheme 96
6. Secure (3362) valve spring compressor to cylinder head with tool securing bolt and position installing tool for compressing valve springs to following positions. Outer intake valves: lower position, Center intake valve: upper position and Exhaust valve: lower position. see scheme 96
7. Connect pressure hose to compressed air system supplying at least 6 bar (87 psi) and remove valve springs.
8. Remove valve stem seals with puller (3364) for valve shaft seal. (Scheme 232)

Valves Stem Seals Installing (Head Installed)

1. Slide plastic sleeve (A) supplied over relevant valve stem. This will prevent the new valve stem seal (B) from being damaged. see scheme 98
2. Place new valve stem seal into installation tool (3365).
3. Oil valve stem seal sealing lip and press carefully onto the valve guide. see scheme 98 To assemble, reverse removal procedures. CAUTION: DO NOT start engine for about 30 minutes after installing camshafts. Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate crankshaft by hand 2 full revolutions before starting engine to ensure valves do not strike pistons.

Scheme 224

Valve lifter operation is checked with lifters installed in vehicle. See VALVE LIFTERS under REMOVAL & INSTALLATION.

Fitting Pistons

1. Measure cylinder bore diameter in 3 places: at center of bore and.39" (10 mm) from top and bottom of bore. If cylinder bore diameter is not within specification, hone cylinder bore until diameter meets first oversize specification. See «CYLINDER BLOCK»(ref-147486-S02992587142002091600000) table under ENGINE SPECIFICATIONS.
2. Measure piston diameter at 90-degree angle to piston pin, about.39" (10 mm) from bottom of piston skirt. see scheme 99 If piston diameter is not within specification, replace piston. See «PISTONS, PINS & RINGS»(ref-147486-S41851760282002091600000) table under ENGINE SPECIFICATIONS. When measuring piston diameter, maximum allowable difference between actual measurement and standard specification is.0016" (.04 mm).

Scheme 225

Scheme 226

1. Install piston ring with TOP mark (if present) facing upward. Insert ring from bottom of cylinder block to a depth of about.591" (15 mm) to measure ring end gap. see scheme 100
2. Measure ring side clearance. see scheme 101 If ring end gap and side clearance are not within specification, replace ring and/or piston as necessary. See «PISTONS, PINS & RINGS»(ref-147486-S41851760282002091600000) table under ENGINE SPECIFICATIONS. Space ring end gaps 120 degrees apart.

Scheme 227

Scheme 228

1. Mark connecting rod and piston assemblies to identify which cylinder they belong to.
2. If replacing rods, replace entire set.
3. Replace bearing cap bolts and nuts with NEW nuts and bolts after each use.
4. Ensure arrow on piston (top or bottom) faces front end of engine when piston is installed.
5. A serrated connecting rod was placed into production on some engines starting in 1998. To identify the connecting rod type see scheme 102
6. The different design connecting rods use different size bolts. The serrated connecting rod uses M8 and M8.5 bolts. ALWAYS measure the threads as different tightening torques are used. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).
7. Make sure connecting rods are installed in original positions. see scheme 103
8. If piston pin is difficult to remove, heat piston to 140°F (60°C).

Connecting Rod Bearings

1. If using Plastigage to check rod bearing oil clearance, DO NOT fully tighten bearing cap bolts. Instead, tighten bolts to 15 ft. lbs. (20 N.m). (Scheme 226) Lubricate threads and contact surface.
2. If rod bearing oil clearance is not within specification, replace rod bearings. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-147486-S04651844112002091600000) table under ENGINE SPECIFICATIONS.
3. Replace rod bearing cap bolts after first use. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).

Scheme 229

1. Main bearing cap No. 1 is located at front (timing belt) end of engine. Main bearing cap No. 4 is located at rear of engine. see scheme 104
2. If main bearing oil clearance is not within specification, replace main bearings with oversize bearings. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-147486-S04651844112002091600000) table under ENGINE SPECIFICATIONS.
3. Do NOT reuse main bearing cap bolts. Install main bearing cap side bolts hand tight before fully tightening them. (Scheme 227) Replace main bearing cap bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).

Thrust Bearing

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 227)

Mount dial indicator on oil pump with plunger contacting crankshaft web. Push crankshaft toward dial indicator. Zero dial indicator. Push crankshaft away from dial indicator. If measured distance (end play) is not within specification, replace thrust bearing and/or crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

Measure cylinder bore diameter in 3 places: at center of bore and.39" (10 mm) from top and bottom of bore. see scheme 105 If cylinder bore diameter is not within specification, hone cylinder bore until diameter meets first oversize specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. When measuring cylinder bore, maximum allowable difference between actual measurement and standard specification is.0031" (.08 mm).

Scheme 230

Oil Pressure

With engine oil temperature at least 176°F (80°C), oil pressure should be 29 psi (2.0 bar) minimum at 2000 RPM.

Oil Viscosity & Type

Use a multi-grade oil with an API specification of at least SJ or SL. To select correct oil viscosity, see .

Scheme 231

OIL PUMP

Note. Two types of oil pumps where used on the 1997-98 AHA engine, the early flange type is driven off the snout of the crankshaft with cogs that engage the oil pump. The oil pump is part of front engine cover (flange). The second later chain driven type is used on both the AHA and ATQ engine and is driven by a chain, turned via a gear on the crankshaft. The oil pump is located in the oil pan.

Note. For help in identifying components and component locations, refer to illustrations. (Scheme 228)and (Scheme 230).

Checking Procedure

1. Insert a screwdriver between chain and chain tensioner and pry carefully against tensioner in direction of arrow. see scheme 112
2. If there is no spring tension or drive chain is slack, chain tensioner is malfunctioning and must be replace. To replace tensioner, timing belt and front engine cover must be removed. See «OIL PUMP»(ref-147486-S38210755722002091600000).

Scheme 232