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2.0l - Crankshaft, Cylinder Block - Engine Code(s): Bpy (coupe) Audi TT 8J

Mechanical 58 illustrations ~3974 words

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 178

Scheme 178: RIBBED BELT AND ASSEMBLY BRACKET OVERVIEW
Scheme 178: RIBBED BELT AND ASSEMBLY BRACKET OVERVIEW
  1. Vibration Damper For the ribbed belt Removing and installing, refer to «VIBRATION DAMPER»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__vibration-damper)
  2. Bolt Replace. 10 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 locking pin T10060A
  5. Bracket for Assemblies Removing and installing, refer to «ACCESSORY ASSEMBLY BRACKET»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__accessory-assembly-bracket) Tightening sequence (Scheme 180)
  6. Bolt 23 Nm
  7. Nut 23 Nm
  8. Generator Removing and installing, refer to «[For transmission(s) 02E] Removal and Installation»(/audi/tt/8j-2006-2010/remont/charging-system/#battery-starter-generator-cruise-control-coupe) 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. Tightening sequence (Scheme 180)
  10. Bushing 2 pieces
  11. Bolt 25 Nm
  12. Air Conditioning (A/C) Compressor Removing and installing, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/automatic-hvac-system/#air-conditioning-coupe)
  13. Ribbed Belt Ribbed belt routing (Scheme 179)Check for wear Do not kink Removing and installing, refer to «RIBBED BELT»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__ribbed-belt)

Scheme 179

Scheme 179
Scheme 179

Scheme 180

Scheme 180
Scheme 180

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

Tighten bolts -1 through 6- to 40 Nm.

Scheme 181

Scheme 181: FRONT SEALING FLANGE OVERVIEW
Scheme 181: FRONT SEALING FLANGE OVERVIEW
  1. Bolt Replace 90 Nm plus an additional 90° ( 1 / 4 turn) Do not oil Fastening counter-holder 3415 (Scheme 183)
  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 182)
  4. Seal Removing and installing, refer to «CRANKSHAFT SEAL, BELT PULLEY SIDE»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__crankshaft-seal-belt-pulley-side). Do not oil
  5. Sealing Flange, Front Must sit on alignment pins Removing and installing, refer to «FRONT SEALING FLANGE»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__front-sealing-flange)
  6. Alignment Pins
  7. Toothed Belt Gear Diamond Disc Replace after removing toothed belt gear
  8. Bolt Tightening sequence (Scheme 182)
  9. Cylinder Block Crankshaft, removing and installing, refer to «CRANKSHAFT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__crankshaft-overview) Piston and connecting rod, disassembling and assembling, refer to «PISTONS AND CONNECTING ROD OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe)

Scheme 182

Scheme 182
Scheme 182

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

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

Tighten bolts -7 through 10- to 15 Nm.

Scheme 183

Scheme 183
Scheme 183

REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL OVERVIEW

Note. Servicing clutch, refer to Description and Operation .

Scheme 184

Scheme 184: REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL OVERVIEW
Scheme 184: REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL OVERVIEW
  1. Bolt Replace 60 plus an additional 90° ( 1 / 4 turn) For dual-mass flywheel/drive plate
  2. Dual Mass Flywheel Dual mass flywheel, removing and installing, refer to «DUAL MASS FLYWHEEL»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__dual-mass-flywheel) 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 186)
  4. Bolt Tightening sequence (Scheme 185)
  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»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__rear-sealing-flange) 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 185)
  8. Cylinder Block Crankshaft, removing and installing, refer to «CRANKSHAFT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__crankshaft-overview) Piston and connecting rod, disassembling and assembling, refer to «PISTONS AND CONNECTING ROD OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe)

Scheme 185

Scheme 185
Scheme 185

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

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

Tighten bolts -7 and 8- to 15 Nm.

Scheme 186

Scheme 186
Scheme 186

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 ASSEMBLY STAND .

Scheme 187

Scheme 187: CRANKSHAFT OVERVIEW
Scheme 187: CRANKSHAFT OVERVIEW
  1. Bolt Replace 65 Nm plus an additional 90° ( 1 / 4 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° ( 1 / 4 turn) Replace sensor wheel every time bolts are loosened (Scheme 188)
  4. Needle Bearing For vehicles with manual transmission Pulling out and driving in, refer to «NEEDLE BEARING FROM CRANKSHAFTS»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__needle-bearing-from-crankshafts)
  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 188)
  6. Crankshaft After removal, place in such a way that it does not rest on sensor wheel -5- and damage it Axial clearance, refer to «CRANKSHAFT, MEASURING AXIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__crankshaft-measuring-axial-play) Radial clearance, refer to «CRANKSHAFT, MEASURING RADIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__crankshaft-measuring-radial-play) Do not turn crankshaft when measuring radial play Crankshaft dimensions, refer to «CRANKSHAFT DIMENSIONS»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__crankshaft-dimensions)
  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 BEARING FROM CRANKSHAFTS»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__needle-bearing-from-crankshafts)
  9. Chain Sprocket For chain for oil pump Removing and installing, refer to «CHAIN SPROCKET»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__chain-sprocket)
  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 188

Scheme 188
Scheme 188

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

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 bolts. Installation of sensor wheel is only possible in one position - the bores are offset.

  1. Tightening specifications, refer to «CRANKSHAFT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__crankshaft-overview)

Scheme 189

Scheme 189
Scheme 189

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.

G=Yellow
B=Blue
W=White

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 190

Scheme 190: PISTONS AND CONNECTING ROD OVERVIEW
Scheme 190: PISTONS AND CONNECTING ROD OVERVIEW
  1. Connecting Rod Bolt Replace 30 Nm plus an additional 90° ( 1 / 4 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 195)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
  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) Use pilot drift VW 222 A for removal and installation
  9. Piston Checking (Scheme 193)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»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__piston-and-cylinder-dimensions) Cylinder bore, checking (Scheme 194)
  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 191)Check piston ring groove clearance (Scheme 192)

Scheme 191

Scheme 191
Scheme 191

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

Piston Ring Dimensions in mmNewWear Limit
Compression ring0.20 to 0.400.8
Oil scraping ring0.25 to 0.500.8

Scheme 192

Scheme 192
Scheme 192

Clean the ring groove of piston before checking.

Piston Ring Dimensions in mmNewWear Limit
Compression ring0.06 to 0.090.20
Oil scraping ring0.03 to 0.060.15

Scheme 193

Scheme 193
Scheme 193

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 194

Scheme 194
Scheme 194

Special tools and workshop equipment required

  1. Internal dial gauge 50 to 100 mm.
  2. Inside Micrometer Set 18-100 mm US1033/S

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

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

Scheme 195

Scheme 195
Scheme 195

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.

CRANKSHAFT DIMENSIONS

(Dimensions in mm)

Honing DimensionCrankshaft Bearing Pin DiameterConnecting Rod Bearing Pin Diameter
0.0170.022
Basic dimension54.0047.80
0.0370.042
0.0170.022
1st oversize53.7547.55
0.0370.042
0.0170.022
2nd oversize53.5047.30
0.0370.042
0.0170.022
Stage III53.2547.05
0.0370.042

PISTON AND CYLINDER DIMENSIONS

Honing DimensionPiston DiameterCylinder Bore Diameter
Basic dimensionMm82.465 1)82.51
1) Measurements without graphite coating (thickness = 0.02 mm). The graphite coating wears off.

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
A/C Compressor25
Bearing Cap 165 + 90°
Connecting Rod Bearing Cap 1, 230 + 90°
Dual Mass Flywheel 160 + 90°
Generator, Bolt/Nut23
Pressure Relief Valve27
Ribbed Belt Tensioning Damper23
Sensor Wheel 110 + 90°
Vibration Damper 110 + 90°
1 Always replace 2 Lubricate threads

Accessory Assembly Bracket Tightening Sequence

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

Tighten bolts -1 through 6- to 40 Nm.

Tightening Sequence of Front Sealing Flange

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

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

3. Tighten bolts -7 through 10- to 15 Nm.

Rear Tightening Sequence

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

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

3. Tighten bolts -7 through 8- to 15 Nm

CRANKSHAFT, MEASURING AXIAL PLAY

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 VW 387 to cylinder block and set indicator against crankshaft counterweight.

Scheme 196

Scheme 196
Scheme 196

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

Press crankshaft off gauge and read value.

Axial clearance

  1. New: 0.07 to 0.23 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 main bearing cap and clean 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 main bearing cap and tighten it to 65 Nm. Do not rotate the crankshaft when doing so.

Remove main bearing caps again.

Compare width of Plastigage with measuring scale.

Radial clearance

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

RIBBED BELT

Special tools and workshop equipment required

  1. Locking Pin T10060A

Removing

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Scheme 197

Scheme 197
Scheme 197

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Pull the Evaporative Emission (EVAP) canister with connected lines upward -arrow- out of the retainer and lay it aside.

Scheme 198

Scheme 198
Scheme 198

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.

Mark the rotation direction on the ribbed belt.

Pivot the ribbed belt tensioner in direction of -arrow- to relieve tension on ribbed belt.

Scheme 199

Scheme 199
Scheme 199

Secure tensioning element using the T10060A.

Scheme 200

Scheme 200
Scheme 200

Remove the ribbed belt.

Installing

Install in reverse order of removal. Note the following

Note. Make sure, before installing ribbed belt, that all ancillaries (generator and Air Conditioner (A/C) compressor) are secured tightly.

Place ribbed belt onto belt pulleys of crankshaft and A/C compressor.

Place ribbed belt onto generator belt pulley lastly, and release tensioner.

Check ribbed belt for correct positioning.

Start the engine and check the belt running.

ACCESSORY ASSEMBLY BRACKET

Special tools and workshop equipment required

  1. Locking Pin T10060A

Removing

Disconnect the electrical connector on the mass airflow (MAF) sensor -G70- -3-.

Open clips -1 and 2- and remove air guide hose from MAF sensor.

Remove front air intake connector on lock carrier -4-.

Remove engine cover.

Pull the Evaporative Emission (EVAP) canister with connected lines upward -arrow- out of the retainer and lay it aside.

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.

Pivot the ribbed belt tensioner in direction of -arrow- to relieve tension on ribbed belt.

Secure tensioning element using the T10060A.

Remove ribbed belt.

Remove ribbed belt tensioner -arrows-.

Scheme 201

Scheme 201
Scheme 201

Discharge the refrigerant circuit. Refer to Description and Operation .

Remove center noise insulation fasteners -1 to 4-.

Scheme 202

Scheme 202
Scheme 202

Remove the right noise insulation -arrows-.

Scheme 203

Scheme 203
Scheme 203

Remove noise insulation frame -arrow-.

Scheme 204

Scheme 204
Scheme 204

Remove the A/C compressor. Refer to Removal and Installation .

Remove the accessory assembly bracket - bolts -1 through 6-.

Installing

Installation is performed in the reverse order of removal, noting the following.

  1. For the correct tightening specifications, refer to «RIBBED BELT AND ASSEMBLY BRACKET OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__ribbed-belt-and-assembly-bracket-overview) .

Tighten the bolts in the sequence -1 through 6-.

Install the generator. Refer to [For transmission(s) 02E] Removal and Installation

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

Install the ribbed belt. Refer to RIBBED BELT .

Connect the battery. Refer to [For transmission(s) 02E] Removal and Installation .

VIBRATION DAMPER

Removing

  1. Ribbed belt removed, refer to «RIBBED BELT»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__ribbed-belt) .

Remove center noise insulation fasteners -1 through 4-.

Remove the right noise insulation -arrows-.

Remove noise insulation frame -arrow-.

Remove vibration damper.

Scheme 205

Scheme 205
Scheme 205

Note. To loosen and tighten vibration damper, counterhold at centering bolt with open end wrench.

Installing

Install in reverse order of removal. Note the following

  1. For the correct tightening specifications, refer to «RIBBED BELT AND ASSEMBLY BRACKET OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__ribbed-belt-and-assembly-bracket-overview)

Install vibration damper using only original equipment bolts.

Scheme 206

Scheme 206
Scheme 206
  1. Only possible to install in one position: The vibration damper crankshaft hole -arrow- must be positioned over the protrusion on the toothed belt sprocket.

CRANKSHAFT SEAL, BELT PULLEY SIDE

Special tools and workshop equipment required

  1. Seal Remover 3203
  2. Counter Support 3415
  3. Assembly Tool T10053
  4. Torque Wrench 5-50 Nm V.A.G 1331
  5. Torque Wrench 40-200 Nm V.A.G 1332

REMOVING

Remove ribbed belt. Refer to RIBBED BELT .

Loosen crankshaft toothed belt gear. To do this, lock toothed belt sprocket with the 3415.

Scheme 207

Scheme 207: REMOVING
Scheme 207: REMOVING

Remove the crankshaft-toothed belt sprocket center bolt -1- -2- and remove the toothed belt sprocket.

Scheme 208

Scheme 208
Scheme 208

Remove diamond disc -3- from toothed belt gear.

To guide seal puller, thread center bolt into crankshaft by hand until stop.

Unscrew inner part of the 3203 nine rotations (approximately 20 mm) from outer part and secure with knurled-head bolt.

Lubricate threaded head of the 3203, position and forcefully screw into seal as far as possible.

Scheme 209

Scheme 209
Scheme 209

Loosen knurled 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

INSTALLING

  1. For the correct tightening specifications, refer to «FRONT SEALING FLANGE OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe)

Clean running and sealing surface.

Before installing, remove oil remains from end of crankshaft with a clean cloth.

Position guide sleeve T10053/1 of the T10053 on end of crankshaft.

Scheme 210

Scheme 210
Scheme 210

Slide seal over guide sleeve onto the crankshaft pin.

Press in the seal using center bolt of toothed belt sprocket and pressure sleeve of the T10053 until it is flush.

Scheme 211

Scheme 211
Scheme 211

Install crankshaft toothed belt gear -2- with new diamond disc -3- and new center bolt -1-.

Note. Contact surface between toothed belt gear, diamond disc and crankshaft must be free of oil. Do not oil the bolt for crankshaft toothed belt sprocket.

Use the 3415 to tighten crankshaft toothed belt gear.

Install toothed belt (adjust timing). Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Install the ribbed belt. Refer to RIBBED BELT .

FRONT SEALING FLANGE

Special tools and workshop equipment required

  1. Counter Support 3415
  2. Assembly Tool T10053
  3. Torque Wrench 5-50 Nm V.A.G 1331
  4. Torque Wrench 40-200 Nm V.A.G 1332
  5. Hand drill with plastic brush attachment
  6. Protective eyewear
  7. Sealant.

Removing

Remove ribbed belt. Refer to RIBBED BELT .

Loosen crankshaft toothed belt gear. To do this, lock toothed belt sprocket with the 3415.

Remove the crankshaft-toothed belt sprocket center bolt -1- -2- and remove the toothed belt sprocket.

Remove diamond disc -3- from toothed belt gear.

Remove the bolts -1 through 10-.

Pry off and remove front sealing flange.

Drive out the seal from the removed flange.

Installing

  1. Tightening specifications, refer to «FRONT SEALING FLANGE OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe)

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

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

WARNINGWear safety glasses.

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

Scheme 212

Scheme 212
Scheme 212

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

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

Scheme 213

Scheme 213
Scheme 213

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

Scheme 214

Scheme 214
Scheme 214

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

Scheme 215

Scheme 215
Scheme 215
  1. Thickness of sealant bead: 2 to 3 mm.
CAUTIONRisk of plugging oil pump strainer with excess sealant. Do not apply sealant bead thicker than indicated.

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.

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

Scheme 216

Scheme 216
Scheme 216

Note. The sealing flange must be installed within 5 minutes of being applied with sealant.

Carefully slide sealing flange onto reamed bolt at cylinder block.

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

Tighten sealing flange bolts in 3 stages as follows

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

Tighten bolts -1 through 6- in a diagonal sequence in stages.

Tighten bolts -7 through 10-.

Install the crankshaft seal -belt pulley side- INSTALLING .

Install crankshaft toothed belt gear -2- with new diamond disc -3- and new center bolt -1-.

Note. Contact surface between toothed belt gear, diamond disc and crankshaft must be free of oil. Do not oil the bolt for crankshaft toothed belt sprocket.

Use the 3415 to tighten crankshaft toothed belt gear.

The rest of the installation is performed in reverse order of removal, noting the following

How to install toothed belt and adjust valve timing. Refer to TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD .

Install vibration damper. Refer to VIBRATION DAMPER .

Install the ribbed belt. Refer to RIBBED BELT .

DUAL MASS FLYWHEEL

Special tools and workshop equipment required

  1. Flywheel Retainer 3067

Removing

CAUTIONTo 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.

Mark the dual-mass flywheel to the engine.

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

Scheme 217

Scheme 217
Scheme 217

When removing bolts -B-, make sure the bolt head does not come into contact with the dual-mass flywheel -arrows- or the flywheel could be damaged when turning the bolt.

Insert the 3067 into hole in cylinder block -B-.

Scheme 218

Scheme 218
Scheme 218

Remove the dual-mass flywheel.

Installing

Install in reverse order of removal. Note the following

  1. Tightening specifications, refer to «REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__rear-sealing-flange-and-dual-mass-flywheel)

Secure with new bolts.

Insert the 3067 into hole in cylinder block -A-.

REAR SEALING FLANGE

Special tools and workshop equipment required

  1. Hand drill with plastic brush attachment
  2. Protective eyewear
  3. Sealant.

Removing

  1. Transmission removed.

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

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

Remove the bolts -1 through 8-.

Pull off the rear sealing flange.

Installing

  1. For the correct tightening specifications, refer to «REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#20l-crankshaft-cylinder-block-engine-codes-bpy-coupe__rear-sealing-flange-and-dual-mass-flywheel) .

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

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

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

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

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

Scheme 219

Scheme 219
Scheme 219

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

Scheme 220

Scheme 220
Scheme 220
CAUTIONRisk of plugging oil pump strainer with excess sealant. Do not apply sealant bead thicker than indicated.

Note. The sealing flange must be installed within 5 minutes of being applied with sealant.

To install, push the sealing flange -2- together with the guide sleeve -1- (included with replacement part) onto the crankshaft.

Scheme 221

Scheme 221
Scheme 221

Then carefully push the sealing flange onto the locating pins on the cylinder block.

Fasten the bolts in the specified order

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

Tighten bolts -1 through 6- in a diagonal sequence in stages.

Tighten bolts -7 through 8-.

The rest of the installation is performed in reverse order of removal, noting the following

Hook in intermediate plate at sealing flange and push it onto the alignment sleeves -arrows-.

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

NEEDLE BEARING FROM CRANKSHAFTS

Special tools and workshop equipment required

  1. Puller T10055
  2. With Adapter T10055/3
  3. Centering Mandrel 3176
  4. or Drift VW 207 C
  5. Extractor for example Kukko 21/2

Removing

Pull out using standard extractor for example Kukko 21/2 -arrow-, T10055/3 and T10055.

Scheme 222

Scheme 222
Scheme 222

Installing

Note. Side of needle bearing with writing on it must be readable when installed.

Drive in using the VW 207 C or 3176.

Scheme 223

Scheme 223
Scheme 223

Installation depth dimension -a- = 2 mm

Scheme 224

Scheme 224
Scheme 224

CHAIN SPROCKET

Special tools and workshop equipment required

  1. Press Tube 30 - 100
  2. Thrust Piece 40 - 105
  3. Two-arm puller, commercially available
  4. Protective gloves

Removing

Remove oil pan with oil pump. Refer to OIL PAN .

Remove front sealing flange. Refer to FRONT SEALING FLANGE .

Pull off crankshaft chain sprocket with claw puller -2- for example Kukko 44-1, while protecting end of crankshaft with the 40 - 105.

Scheme 225

Scheme 225
Scheme 225

Installing

Install in reverse order of removal. Note the following

WARNINGWear protective gloves!

Heat up the chain sprocket in an oven for approximately 15 minutes at 220 °C (428 °F).

Note. Installation position: Wider shoulder of chain sprocket faces toward engine.

Using pliers, install chain sprocket on crankshaft end and slide onto crankshaft to stop using the 30 - 100.

Scheme 226

Scheme 226
Scheme 226

Install oil pan with oil pump. Refer to OIL PAN .

Scheme 227

Scheme 227: SPECIAL TOOLS
Scheme 227: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Seal Remover 3203
  2. Counter Support 3415
  3. Assembly Tool T10053
  4. Torque Wrench 5-50 Nm V.A.G 1331
  5. Torque Wrench 40-200 Nm V.A.G 1332

Special tools and workshop equipment required

Scheme 228

Scheme 228
Scheme 228

Scheme 229

Scheme 229
Scheme 229

Scheme 230

Scheme 230
Scheme 230

Scheme 231

Scheme 231
Scheme 231

Scheme 232

Scheme 232
Scheme 232

Scheme 233

Scheme 233
Scheme 233

Scheme 234

Scheme 234
Scheme 234

Scheme 235

Scheme 235
Scheme 235
  1. Dial Gauge Holder VW 387
  2. Dial Gauge 0-10 mm VAS 6079
  3. Locking Pin T10060A
  4. Flywheel Retainer 3067
  5. Puller T10055
  6. With Adapter T10055/3
  7. Centering Mandrel 3176
  8. Press Tube 30 - 100
  9. Thrust Piece 40 - 105
  10. Drift VW 207 C

See also:
• [For transmission(s) 02E] Removal and Installation
• Removal and Installation
• Description and Operation
• ENGINE, SECURING TO ASSEMBLY STAND
• Description and Operation
• TOOTHED BELT DRIVE, WITHOUT DIVIDED TOOTHED BELT GUARD OVERVIEW
• TOOTHED BELT, WITHOUT DIVIDED TOOTHED BELT GUARD
• OIL PAN
• VIBRATION DAMPER
• ACCESSORY ASSEMBLY BRACKET
• RIBBED BELT
• CRANKSHAFT SEAL, BELT PULLEY SIDE
• FRONT SEALING FLANGE
• CRANKSHAFT OVERVIEW
• PISTONS AND CONNECTING ROD OVERVIEW
• DUAL MASS FLYWHEEL
• REAR SEALING FLANGE
• NEEDLE BEARING FROM CRANKSHAFTS
• CRANKSHAFT, MEASURING AXIAL PLAY
• CRANKSHAFT, MEASURING RADIAL PLAY
• CRANKSHAFT DIMENSIONS
• CHAIN SPROCKET
• PISTON AND CYLINDER DIMENSIONS
• RIBBED BELT AND ASSEMBLY BRACKET OVERVIEW
• INSTALLING
• REAR SEALING FLANGE AND DUAL-MASS FLYWHEEL OVERVIEW

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