2.0l - Crankshaft, Cylinder Block - Engine Code(s): Caeb (sedan) Audi A4 B8

Scheme 1

1. Ribbed Belt Check for wear Do not kink Ribbed belt routing (Scheme 3)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/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__ribbed-belt) When installing, make sure it is seated correctly on the pulleys
2. Idler Roller 20 Nm
3. Bolt 150 Nm + 90° turn Replace Coat the O-ring with oil Use counter hold tool T10355 to loosen and tighten CAUTION: The engine could be destroyed. Do not turn the crankshaft when a bolt is removed because this will offset the timing.
4. O-ring No replacement part, part of the bolt delivery package
5. Vibration Damper With ribbed belt pulley Removing and installing, refer to «VIBRATION DAMPER»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__vibration-damper) CAUTION: The engine could be destroyed. In order not to change the valve timing, the crankshaft must not be moved out of the "TDC" position when the vibration damper is removed.
6. Bolt 40 Nm
7. Ribbed Belt Tensioning Damper To release tension on ribbed belt, pivot using a wrench. Secure it with locking toolT40098 Removing and installing, refer to «RIBBED BELT TENSIONING DAMPER»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__ribbed-belt-tensioning-damper)
8. Bracket for Assemblies With oil filter and engine oil cooler Accessory assembly bracket, removing and installing, refer to «ACCESSORY ASSEMBLY BRACKET»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__accessory-assembly-bracket) For removing and installing engine oil cooler, refer to «ENGINE OIL COOLER»(/audi/a4/b8-2007-2012/remont/lubrication-system/#20l-lubrication-engine-codes-caeb-sedan__engine-oil-cooler)
9. Generator Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/charging-system/#battery-starter-generator-cruise-control-sedan)
10. Bolt Tightening specifications, refer to «Specifications»(/audi/a4/b8-2007-2012/remont/charging-system/#battery-starter-generator-cruise-control-sedan)
11. Bolt Tightening sequence (Scheme 2)
12. Bolt Tightening specifications, refer to «Specifications»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan)
13. Sleeve
14. Power Steering Pump Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan)
15. Air Conditioning (A/C) Compressor Do not remove or disconnect refrigerant lines Removing and installing, refer to «Removal and Installation»(/audi/a4/b8-2007-2012/remont/automatic-hvac-system/#air-conditioning-sedan)
16. Bolt Tightening specifications, refer to «Description and Operation»(/audi/a4/b8-2007-2012/remont/automatic-hvac-system/#air-conditioning-sedan)
17. Alignment Bushing For air conditioning compressor
18. Bolt Tightening specifications, refer to «Specifications»(/audi/a4/b8-2007-2012/remont/manual-power-steering/#steering-sedan)

Scheme 2

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

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

Scheme 3

1. Vibration damper
2. Idler roller
3. Ribbed belt tensioning damper
4. Generator
5. Power steering pump
6. A/C compressor

Scheme 4

1. Cylinder Block
2. Sealing Flange with Seal Replace, refer to «SEALING FLANGE, TRANSMISSION SIDE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__sealing-flange-transmission-side) Do not oil or grease the sealing lip of seal Before installing, remove oil remains from crankshaft journal with a clean cloth
3. Bolt Tightening sequence with 8 bolts (Scheme 5)Tightening sequence with 6 bolts (Scheme 6)
4. Drive Plate To loosen the bolts, secure with 3067
5. Bolt 60 Nm + 90° turn Replace
6. Needle Bearing For removing and installing the needle bearing, refer to «NEEDLE BEARING ON DRIVE PLATE, MANUAL TRANSMISSION»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__needle-bearing-on-drive-plate-manual)
7. Intermediate Plate Must be located on dowel sleeves Be careful not to damage or bend when installing Is hooked in at sealing flange (Scheme 7)
8. Alignment Sleeve Quantity: 2

Scheme 5

Tighten bolts -1 through 8- in the sequence shown

1. Tighten the bolts hand-tight.

2. Tighten the bolts to 9 Nm.

Scheme 6

Tighten new bolts -1 through 6- in the sequence shown

1. Tighten the bolts hand-tight.

2. Tighten the bolts to 4 Nm + 45°.

Note. Only 6 bolts are installed, 2 bolt openings remain open.

Scheme 7

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 TO ENGINE STAND .

Scheme 8

1. Cylinder Block
2. Bearing Shell for Cylinder Block With lubricating groove Lubricate Do not interchange used bearing shells (mark) Crankshaft bearing shells identification (classification), refer to «ALLOCATION OF THE CRANKSHAFT BEARING SHELLS (CLASSING)»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__allocation-of-the-crankshaft-bearing-shells)
3. Crankshaft After removal, lay aside so that sensor wheel, refer to item 8 is not rested on and becomes damaged If the crankshaft is being replaced, then the bearing shells must be allocated to the bearing cover, refer to «ALLOCATION OF THE CRANKSHAFT BEARING SHELLS (CLASSING)»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__allocation-of-the-crankshaft-bearing-shells) Axial clearance, refer to «CRANKSHAFT, MEASURING AXIAL CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__crankshaft-measuring-axial-clearance) Radial clearance, refer to «CRANKSHAFT, MEASURING RADIAL PLAY»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__crankshaft-measuring-radial-play) Do not turn crankshaft when measuring radial play Crankshaft dimensions, refer to «CRANKSHAFT DIMENSIONS»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__crankshaft-dimensions)
4. Bearing Shell for Bearing Cap Without lubricating groove Lubricate Do not interchange used bearing shells (mark) Crankshaft bearing shells identification (classification), refer to «ALLOCATION OF THE CRANKSHAFT BEARING SHELLS (CLASSING)»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__allocation-of-the-crankshaft-bearing-shells)
5. Bolt Replace Tightening sequence (Scheme 9)
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 10 Nm + 90° turn Replace Replace sensor wheel every time bolts are loosened, refer to «SENSOR WHEEL»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__sensor-wheel)
8. 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, refer to «SENSOR WHEEL»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__sensor-wheel)
9. Thrust Washers Lubricate For bearing 3
10. Bolt Replace Tightening sequence (Scheme 9)

Scheme 9

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

Tighten the bolts -1 through 10- and -arrows A- 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 A- to 20 Nm.

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

ALLOCATION OF THE CRANKSHAFT BEARING SHELLS (CLASSING)

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 10

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

Bearing Cap Bearing Shell Identification

Scheme 11

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

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

Scheme 12

1. Connecting Rod Bolt 45 Nm + 90° turn Replace Lubricate the 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 Pay attention to the installed position Due to the separation procedure (cracking) of the connecting rod, the connecting rod bearing cap only fits in one position and only to the corresponding connecting rod. Mark affiliation to cylinder -A- Installation position: Markings -B- point to belt pulley side Separate new connecting rod, refer to «NEW CONNECTING ROD, SEPARATING»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__new-connecting-rod-separating)
3. Bearing Shells Installed location (Scheme 14)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 Do not bend the oil injector jet Replace the oil spry nozzles if they are bent
6. Circlip Replace
7. Piston Pin
8. Piston Removing and installing, refer to «PISTON»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__piston) Mark installed position and cylinder allocation Arrow on piston face points toward belt pulley side Pistons and cylinder bore, checking, refer to «PISTONS AND CYLINDER BORE, CHECKING»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan)
9. Compression Rings Use commercially available piston ring pliers for removing and installing Offset gaps by 120° Installed position: Identification "TOP" or "R" towards piston crown Checking ring gap (Scheme 19)Check piston ring groove clearance (Scheme 20)
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 (Scheme 19)Side clearance cannot be measured.
11. Connecting Rod Only replace as set Mark affiliation to cylinder -A- Installation position: Markings -B- point to belt pulley side Separate new connecting rod, refer to «NEW CONNECTING ROD, SEPARATING»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__new-connecting-rod-separating) Radial clearance, measuring, refer to «CONNECTING ROD, MEASURING RADIAL CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__connecting-rod-measuring-radial-clearance)

Scheme 13

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

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

NEW CONNECTING ROD, SEPARATING

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

Clamp the connecting rod in a vise, which has protectors over the grips to prevent damage.

Scheme 14

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

Remove the bolts -arrows- approximately 5 turns.

Carefully tap the connecting rod bearing cap with a plastic hammer -arrow- until it comes loose.

Scheme 15

CRANKSHAFT DIMENSIONS

(Dimensions in mm)

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, with 8 Bolts

Tighten bolts -1 through 8- in the sequence shown

1. Tighten the bolts hand-tight.

2. Tighten the bolts to 9 Nm.

Transmission Side Sealing Flange - Tightening Sequence, with 6 Bolts

Tighten new bolts -1 through 6- in the sequence shown

1. Tighten the bolts hand-tight.

2. Tighten the bolts to 4 Nm + 45°.

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, MEASURING AXIAL CLEARANCE

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge 0-10 mm VAS 6079

Procedure

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

Scheme 16

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

Press crankshaft off gauge and read value.

Axial clearance

1. New: 0.070 to 0.231 mm
2. Wear limit: 0.30 mm

CRANKSHAFT, MEASURING RADIAL PLAY

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 crankshaft bearing cap and clean the bearing cap and pins.

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

1. Plastigage must rest in center of bearing shell.

Position the bearing cap and tighten to 60 Nm without rotating the crankshaft.

Remove the crankshaft bearing cap again.

Compare width of Plastigage with measuring scale.

Radial clearance

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

Scheme 17

Measure approximately 15 mm from the lower edge at a 90° angle to the piston pin axis using a 75 to 100 mm external micrometer.

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

Scheme 18

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

Measure with feeler gauge.

Scheme 19

Clean piston ring groove.

Measure with feeler gauge.

Scheme 20

Special tools and workshop equipment required

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

Note. A shadow or a shiny spot on the wall of the cylinder does not mean the cylinder bore is damaged as long as the cross-grinding is still visible. Always measure the cylinder bore in 3 places laterally and longitudinally using VAS 6078 or US1033/S.

Using a VAS 6078 or US1033/S 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 engine and transmission holderVAS 6095, false measurements are possible.

CONNECTING ROD, MEASURING RADIAL CLEARANCE

Special tools and workshop equipment required

1. Plastigage

Procedure

Remove 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.

Reinstall connecting rod cover.

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 Tool T40098

Removing

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

Scheme 21

Secure the tensioner with the T40098.

Remove ribbed belt.

Installing

Install in reverse order of removal. Note the following

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

Install the ribbed belt as illustrated.

Turn the tensioner in direction of -arrow- and remove the T40098.

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. Locking Tool T40098

Removing

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

Secure the tensioner with the T40098.

Remove the ribbed belt from the tensioner.

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

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «RIBBED BELT DRIVE AND AUXILIARY COMPONENT BRACKET OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan) .

Install the ribbed belt. Refer to RIBBED BELT .

ACCESSORY ASSEMBLY BRACKET

Special tools and workshop equipment required

1. Drip Tray for VAS 6100 VAS 6208
2. Locking Tool T40098

Removing

Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

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

Secure the tensioner with the T40098.

Remove ribbed belt.

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

Note. Place a cloth under the accessory assembly bracket to collect leaking engine oil.

Disconnect the connectors -1 and 4- from the oil pressure switch -F22- and the reduced oil pressure switch -F378-.

Scheme 22

Loosen the hose clamps -arrows- and remove the air guide hose.

Scheme 23

Remove generator. Refer to Removal and Installation .

Disconnect solenoid clutch electrical connector -1- on Air Conditioning (A/C) compressor.

Scheme 24

Remove A/C compressor bolts -arrows-.

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

Note. The power steering pump hydraulic lines remain connected.

Remove the bolts -1- from the front through the belt pulley and then remove the bolt -2- from the back.

Scheme 25

Note. The power steering pump is shown in the illustration without the belt pulley and without the hydraulic lines.

Remove the power steering pump with the hydraulic lines connected on the longitudinal member.

Remove the oil filter -arrow- using the oil filter wrench 3417.

Scheme 26

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

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «RIBBED BELT DRIVE AND AUXILIARY COMPONENT BRACKET OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan) .

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 27

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

Press the accessory assembly bracket -1- onto the connection, mount the bolts and tighten to tightening specification. (Scheme 2)

Install the power steering pump. Refer to Removal and Installation .

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

Install generator. Refer to Removal and Installation .

Install the ribbed belt. Refer to RIBBED BELT .

Fill with coolant. Refer to Filling .

Check the oil level. Refer to MAINTENANCE PROCEDURES

VIBRATION DAMPER

Special tools and workshop equipment required

1. Locking Tool T40098
2. Counter Hold Tool T10355

Removing

Remove the front noise insulation. Refer to Description and Operation .

Remove the coolant fan electrical connector -1- from the bracket and disconnect it by sliding the retainer back -arrow- and pressing the release down.

Scheme 28

Free up the electrical wiring harness to the radiator fan control module.

Disconnect electrical connectors -2 and 3- -3-.

Scheme 29

Remove the bolt -arrow- and the coolant fan control module -1-.

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

Secure the tensioner with the T40098.

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

Rotate the vibration damper using the T10355 into the "OT" position -arrow-.

Scheme 30

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

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «RIBBED BELT DRIVE AND AUXILIARY COMPONENT BRACKET OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan) .

Note. Replace the vibration damper bolt with an O-ring. The O-ring -1- is supplied with the bolt. Coat it with oil before installing.

Coat the sealing lip with engine oil.

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

Install the ribbed belt. Refer to RIBBED BELT .

Install the radiator fan control module -J293-. Refer to RADIATOR FAN CONTROL MODULE .

DRIVE PLATE

Special tools and workshop equipment required

1. Counter Hold Tool 10 - 201

Removing

1. Transmission removed.

Insert the 10 - 201 to loosen the bolts.

Scheme 31

Remove the bolts, drive plate and sensor wheel.

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «SEALING FLANGE AND DRIVE PLATE OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan) .

Note. Replace the drive plate bolts. Manual transmission vehicles have a needle bearing inside the drive plate. Check if the needle bearing is inserted before installing. Needle bearing, removing from and installing on drive plate. Refer to NEEDLE BEARING ON DRIVE PLATE, MANUAL TRANSMISSION .

Be careful of the alignment bushings during installation.

Reposition the 10 - 201 to tighten the bolts.

NEEDLE BEARING ON DRIVE PLATE, MANUAL TRANSMISSION

Special tools and workshop equipment required

1. Tube 31.5 mm Dia.VW 418 A
2. Tube 28 mm Dia. 100 mm VW 421
3. Sleeve 40 - 103

Procedure

1. Transmission removed.

Remove the drive plate. Refer to DRIVE PLATE .

Place the 40 - 103 under the drive plate to remove and install.

Scheme 32

Press the bearing sleeve out using the VW 421 and shop press.

1. The smaller diameter of the VW 421 faces the drive plate.

Carefully press the needle bearing in as far as the stop using the VW 418 A and shop press.

Scheme 33

1. Installation position: the closed side of the needle bearing faces the engine.

Installing drive plate. Refer to DRIVE PLATE .

SEALING FLANGE, TRANSMISSION SIDE

Special tools and workshop equipment required

1. Guide Sleeve T20097
2. Hand drill with plastic brush attachment
3. Protective goggles
4. Sealant

Removing

1. Transmission removed.

Remove the drive plate. Refer to DRIVE PLATE .

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

Remove the bolts -1 through 8

Note. There may be 6 bolts installed, depending on the version.

Remove the transmission side sealing flange.

Installing

1. For the correct tightening specifications, refer to «SEALING FLANGE AND DRIVE PLATE OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan) .

1. Silicone sealant

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

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

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

Cut the tube nozzle at the front marking (nozzle diameter: approximately 2 mm).

Scheme 34

Apply the silicone sealant on the clean sealing surface of the new cover as shown in the illustration.

Scheme 35

1. Thickness of sealant bead: 2 to 3 mm.

Note. The sealing flange must be installed within 5 minutes after application of silicon sealant. 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 36

Slide the sealing flange on the crankshaft flange using the T20097 and tighten the bolts right away, tightening sequence

1. Cover with 8 bolts (Scheme 5)
2. Cover with 6 bolts (Scheme 6)

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

Further assembly is performed in the reverse order of removal, thereby observing the following

Installing drive plate. Refer to DRIVE PLATE .

Check the oil level. Refer to MAINTENANCE PROCEDURES

SENSOR WHEEL

Remove engine.

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

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

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 the sensor wheel.

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

Scheme 37

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 OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan__crankshaft-overview) .

PISTON

Special tools and workshop equipment required

1. Pilot Drift VW 222 A
2. Piston Installation Tool 82.5 mm Bore SET 850

Removing

Removing engine. Refer to ENGINE, REMOVING .

Secure the engine to engine and transmission holder VAS 6095. Refer to ENGINE, SECURING TO ENGINE STAND .

Cylinder head, removing

1. Refer to «CYLINDER HEAD WITH WRENCH CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-sedan__cylinder-head-with-wrench-clearance)
2. Refer to «CYLINDER HEAD WITHOUT WRENCH CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-sedan__cylinder-head-without-wrench-clearance)

Remove the upper oil pan. Refer to UPPER OIL PAN .

Mark the installed position of the piston and the cylinder to which it belongs.

Mark the installed position of the piston and the connecting rod to which it belongs, refer to item 11 .

Remove the connecting rod bearing cap and then remove the piston and connecting rod upward.

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

Remove the circlip from the piston pin.

Remove the piston pin using a VW 222 A.

Installing

Install in reverse order of removal. Note the following

1. Tightening specifications, refer to «PISTON AND CONNECTING ROD OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-caeb-sedan) .

Note. Replace bolts which have been tightened to an additional torque. Arrow on piston face points toward the belt pulley side. Offset the end of the piston ring 120°.

Lubricate the running surfaces on the bearing shells.

Install the piston with a commercially available piston ring compressor. Pay attention to the installed position, refer to item 8 .

Install the connecting rod bearing cap. Pay attention to the installed position, refer to item 2 .

Cylinder Head, Installing

1. Refer to «CYLINDER HEAD WITH WRENCH CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-sedan__cylinder-head-with-wrench-clearance)
2. Refer to «CYLINDER HEAD WITHOUT WRENCH CLEARANCE»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-cylinder-head-valvetrain-engine-codes-caeb-sedan__cylinder-head-without-wrench-clearance)

Install the upper oil pan. Refer to UPPER OIL PAN .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. Guide Sleeve T20097
2. Dial Gauge Holder VW 387
3. Dial Gauge 0-10 mm VAS 6079
4. Locking Tool T40098
5. Drip Tray for VAS 6100 VAS 6208
6. Counter Hold Tool T10355
7. Counter Hold Tool 10 - 201
8. Tube 31.5 mm Dia.VW 418 A
9. Tube 28 mm Dia. 100 mm VW 421
10. Sleeve 40 - 103
11. Pilot Drift VW 222 A
12. Not illustrated
13. Guide Sleeve T20097
14. Piston Installation Tool 82.5 mm Bore SET 850

See also:
• ENGINE OIL COOLER
• Removal and Installation
• Specifications
• Removal and Installation
• ENGINE, SECURING TO ENGINE STAND
• COOLANT, DRAINING AND FILLING
• Filling
• MAINTENANCE PROCEDURES
• Description and Operation
• RADIATOR FAN CONTROL MODULE
• UPPER OIL PAN
• BALANCE SHAFT TIMING CHAIN
• ENGINE, REMOVING
• CYLINDER HEAD WITH WRENCH CLEARANCE
• CYLINDER HEAD WITHOUT WRENCH CLEARANCE
• RIBBED BELT
• VIBRATION DAMPER
• RIBBED BELT TENSIONING DAMPER
• ACCESSORY ASSEMBLY BRACKET
• SEALING FLANGE, TRANSMISSION SIDE
• NEEDLE BEARING ON DRIVE PLATE, MANUAL TRANSMISSION
• ALLOCATION OF THE CRANKSHAFT BEARING SHELLS (CLASSING)
• CRANKSHAFT, MEASURING AXIAL CLEARANCE
• CRANKSHAFT, MEASURING RADIAL PLAY
• CRANKSHAFT DIMENSIONS
• SENSOR WHEEL
• NEW CONNECTING ROD, SEPARATING
• PISTON
• PISTONS AND CYLINDER BORE, CHECKING
• CONNECTING ROD, MEASURING RADIAL CLEARANCE
• DRIVE PLATE
• CRANKSHAFT OVERVIEW