3.2l - Crankshaft, Cylinder Block - Engine Code(s): Cbra (coupe) Audi TT 8J

Scheme 236

1. Ribbed Belt Check for wear Do not kink 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. Removal and installation, refer to «RIBBED BELT»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__ribbed-belt) When installing, make sure it is seated correctly on the pulleys
2. Vibration Damper With ribbed belt pulley Removal and installation, refer to «VIBRATION DAMPER»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__vibration-damper)
3. Bolt Replace 100 Nm plus an additional 180° turn Use counter-holder T10069 to loosen and tighten
4. Bolt 20 Nm
5. Ribbed Belt Pulley for Coolant Pump
6. Bolt 8 Nm
7. Bolt 50 Nm
8. Tensioning Device for Ribbed Belt To release tension on ribbed belt, swing using open-end wrench. Secure with Locking Pin T10060 A Removal and installation, refer to «RIBBED BELT TENSIONER»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__ribbed-belt-tensioner)
9. Coolant Pump Removal and installation, refer to «COOLANT PUMP»(/audi/tt/8j-2006-2010/remont/cooling-fan/#32l-cooling-system-engine-codes-cbra-coupe__coolant-pump)
10. Bracket for Assemblies Removal and installation, refer to «ACCESSORY ASSEMBLY BRACKET»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__accessory-assembly-bracket)
11. Bolt 23 Nm
12. Generator Removal and installation, refer to «[For transmission(s) 02E] Removal and Installation»(/audi/tt/8j-2006-2010/remont/charging-system/#battery-starter-generator-cruise-control-coupe)
13. Bolt 3 pieces Tightening specifications and tightening sequence (Scheme 237)
14. A/C Compressor Fitting Sleeve
15. A/C Compressor Do not remove or disconnect refrigerant lines Removal and installation, refer to «REMOVAL AND INSTALLATION»(/audi/tt/8j-2006-2010/remont/automatic-hvac-system/#air-conditioning-roadster)
16. Bolt 25 Nm
17. Fitting bolt 2 pieces Tightening specifications and tightening sequence (Scheme 237)
18. Idler Roller
19. Bolt 40 Nm

Scheme 237

Tighten bolts in 2 stages in -1 to 5- sequence as follows

Note. Bolts -1- and -2- are fitting bolts.

Scheme 238

Tighten bolts in 3 stages as follows

DUAL-MASS FLYWHEEL COMPONENT OVERVIEW

Note. For assembly work, secure the engine on the engine and transmission holder. Refer to ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER .

Note. Items -4 through 23-, refer to TIMING CHAIN COVERS ASSEMBLY OVERVIEW .

Scheme 239

1. Bolt Replace 60 Nm plus an additional 90° ( 1 / 4 ) turn.
2. Dual Mass Flywheel Removal and installation, refer to «DUAL MASS FLYWHEEL»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__dual-mass-flywheel)
3. Seal Replacing, refer to «CRANKSHAFT SEAL, REPLACING»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__crankshaft-seal-replacing) .

CRANKSHAFT ASSEMBLY OVERVIEW

Note. For assembly work, secure the engine on the engine and transmission holder. Refer to ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER . If a large amount of metal shavings or particles are found when performing engine repairs, these could indicate crankshaft or rod bearings are damaged. To prevent subsequent damage, the following work must be performed after the repair: Oil channels must be cleaned carefully; replace oil spray jets, oil cooler and oil filter.

Scheme 240

1. Cylinder Block Cylinder bore, checking (Scheme 247)Piston and cylinder dimensions, refer to «PISTON AND CYLINDER DIMENSIONS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__piston-and-cylinder-dimensions)
2. Oil Spray Jet for Piston Cooling For crankshaft bearing 2 to 7 Opening pressure 2.0 bar pressure Removal and installation (Scheme 242)
3. Bearing Shell For cylinder block with oil inlet bore Mark used bearing shells Replacement parts are only color coded "yellow"
4. Crankshaft After removal, place in such a way it does not rest on sensor wheel -10- and damage it Measuring axial play, refer to «CRANKSHAFT, MEASURING AXIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__crankshaft-measuring-axial-play) Radial clearance, measuring, refer to «CRANKSHAFT, MEASURING RADIAL PLAY»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__crankshaft-measuring-radial-play) Crankshaft dimensions, refer to «CRANKSHAFT DIMENSIONS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__crankshaft-dimensions) Timing chain wheel built into crankshaft
5. Thrust Washer For bearing 5 Observe locating point Lubricating groove faces crankshaft
6. Bearing Cap Bearing cap 1: Belt pulley side Bearing cap 5 with notches for thrust washers Bearing shell retaining tabs in cylinder block and in bearing cap must align
7. Bolt Replace 30 Nm plus an additional 180° ( 1 / 2 ) turn. Use old bolts for radial play measurement, tighten to 30 Nm but do not tighten further
8. Bearing Shell For bearing cap without oil groove Mark used bearing shells Replacement parts are only color coded "yellow"
9. Thrust Washer For bearing 5 Observe locating point Lubricating groove faces crankshaft
10. Sensor Wheel For Engine Speed (RPM) Sensor -G28- Replace Installing (Scheme 241)
11. Bolt Replace If bolts were removed, replace sensor wheel Tightening specifications and tightening sequence (Scheme 241)

Scheme 241

Note. If sensor wheel bolts were loosened, bolts and sensor wheel must be replaced.

Clean contact surface between crankshaft and sensor wheel, it must be free of oil and grease.

Lightly coat contact surface between crankshaft and sensor wheel with locking compound, locking compound.

Installation position

1. The mark "VR6" -2- must be positioned at the bore of bolt -3-, that goes into the crank pin of the crankshaft (the contour of the crankshaft is shown by the dashed line -1-).
2. The gap -arrow- in the ring gear lies across from the designation.

Note. Ignore the second "VR6" imprint -4-.

Tighten sensor wheel bolts in 3 stages as follows

Tighten bolts by hand.

Tighten the bolt -3- to 10 Nm and an additional 90° ( 1 / 4 turn).

Tighten both other bolts to 10 Nm and an additional 90° ( 1 / 4 turn).

Scheme 242

Scheme 243

1. Bolt Replace Lubricate threads and contact surface 30 Nm plus an additional 90° ( 1 / 4 ) turn. Use old bolts for radial play measurement, tighten to 30 Nm but do not tighten further
2. Connecting Rod Bearing Cap Affiliation to the cylinder mark -B- Installation position: Markings -A- must align
3. Bearing Shells Mark used bearing shells Bearing shell retaining tabs must be firmly seated in the notches Installation position: Retaining tabs of both bearing shells lie on the same side of the connecting rod Measuring axial play, refer to «CONNECTING ROD, MEASURING AXIAL CLEARANCE»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__connecting-rod-measuring-axial-clearance) Radial clearance, measuring, refer to «CONNECTING ROD, MEASURING RADIAL CLEARANCE»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__connecting-rod-measuring-radial-clearance) Replacement parts are color coded "yellow" for lower and "red" for upper
4. Connecting Rod With oil hole for piston pin lubrication Only replace as set Affiliation to the cylinder mark -B- Installation position: -A- markings face toward lower side of piston crown (to center of cylinder block)
5. Circlip
6. Piston Pin If tight, heat piston to 60 °C / 140 °F Removing and installing using a drift VW 222 A
7. Piston Checking (Scheme 246)Mark installed location to connecting rod and affiliation to cylinder Shallow side of piston head faces cylinder block center Piston and cylinder dimensions, refer to «PISTON AND CYLINDER DIMENSIONS»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__piston-and-cylinder-dimensions) Install using fitting tool T10147 (Scheme 248)
8. Piston Rings Compression rings Offset gaps by 120° Use piston ring pliers for removal and installation Mark "TOP" must face toward piston head Checking ring gap (Scheme 244)Check piston ring groove clearance (Scheme 245)
9. Piston Ring Oil scraping ring 3-part Install upper steel ring so gap is offset by 120° to neighboring compression ring Offset all oil scraping ring component gaps to each other

Scheme 244

Slide piston ring from above into lower cylinder opening as follows, using piston without piston ring.

1. Right angle to cylinder wall.
2. Until approximately 15 mm from bottom edge of cylinder.

Measure with feeler gauge.

Scheme 245

Clean piston ring groove.

Measure with feeler gauge.

Scheme 246

Measure with external micrometer 75 to 100 mm as follows

1. Approximately 6 mm from bottom edge.
2. Offset 90° to piston pin axle.

Deviation from nominal dimension

1. Maximum 0.04 mm.

Nominal dimension, refer to PISTON AND CYLINDER DIMENSIONS .

Scheme 247

Measure with internal dial gauge 50 to 100 mm as follows

1. Diagonally at 3 positions transversely -A- and longitudinally -B-.

Deviation from nominal dimension

1. Maximum 0.08 mm.

Nominal dimension, refer to PISTON AND CYLINDER DIMENSIONS .

Scheme 248

Note. If a new Piston Insertion Funnel T10147 is used, pistons must first be guided twice through the funnel with lubricated piston rings and any shavings resulting from this must be removed. Then the pistons can be installed with piston rings.

Push piston by hand into oiled piston installation tool.

1. Flat side of piston crown must face toward funnel pin -arrow-.

Hold funnel (with piston inserted) on upper edge and press piston in with both thumbs.

Push piston in until it protrudes approximately 15 mm from lower edge of funnel.

Place pistons in appropriate cylinder bore.

1. Funnel pin -arrow- must point toward center of cylinder block.

Press funnel tightly against cylinder block and push piston in.

CRANKSHAFT DIMENSIONS

PISTON AND CYLINDER DIMENSIONS

FASTENER TIGHTENING SPECIFICATIONS

Accessory Assembly Bracket - Tightening Specifications and Tightening Sequence

Tighten bolts in 2 stages in -1 to 5- sequence as follows

Note. Bolts -1- and -2- are fitting bolts.

Sealing Flange - Tightening Specifications and Tightening Sequence

Tighten bolts in 3 stages as follows

Install Engine Speed (RPM) Sensor -G28- Sensor Wheel

Note. If sensor wheel bolts were loosened, bolts and sensor wheel must be replaced.

Clean contact surface between crankshaft and sensor wheel, it must be free of oil and grease.

Lightly coat contact surface between crankshaft and sensor wheel with locking compound, locking compound.

Installation position

1. The mark "VR6" -2- must be positioned at the bore of bolt -3-, that goes into the crank pin of the crankshaft (the contour of the crankshaft is shown by the dashed line -1-).
2. The gap -arrow- in the ring gear lies across from the designation.

Note. Ignore the second "VR6" imprint -4-.

Tighten sensor wheel bolts in 3 stages as follows

Tighten bolts by hand.

Tighten the bolt -3- to 10 Nm and an additional 90° ( 1 / 4 turn).

Tighten both other bolts to 10 Nm and an additional 90° ( 1 / 4 turn).

CRANKSHAFT, MEASURING AXIAL PLAY

Special tools and workshop equipment required

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6079

Procedure

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

Scheme 249

Press crankshaft against dial gauge by hand.

Set dial gauge to "0".

Press crankshaft off dial indicator and read the 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 worn down to nickel coating must be replaced.

Remove bearing cap.

Clean bearing cap and bearing journals.

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 the bolts to 30 Nm without rotating the crankshaft.

Reinstall bearing cap.

Compare width of Plastigage with calibrated scale.

Radial clearance

1. New: 0.02 to 0.06 mm.
2. Wear limit: 0.10 mm.

CONNECTING ROD, MEASURING AXIAL CLEARANCE

Special tools and workshop equipment required

1. Feeler gauge

Procedure

Measure with feeler gauge.

Axial clearance

1. New: 0.05 to 0.31 mm.
2. Wear limit: 0.40 mm.

CONNECTING ROD, MEASURING RADIAL CLEARANCE

Remove bearing cap.

Clean bearing cap and bearing journals.

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 the bolts to 30 Nm without rotating the crankshaft.

Reinstall bearing cap.

Compare width of Plastigage with calibrated scale.

Radial clearance

1. New: 0.02 to 0.07 mm.
2. Wear limit: 0.10 mm.

Replace connecting rod bolts.

RIBBED BELT

Special tools and workshop equipment required

1. Locking Pin T10060 A

Removing

Pull the EVAP canister in the engine compartment together with the connected hoses upward out of the bracket -arrow- and lay it to the side.

Scheme 250

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

Scheme 251

Secure tensioner with T10060 A.

Remove ribbed belt.

Installing

Installation is in reverse order of removal, note the following

Note. Before installing ribbed belt, generator, A/C compressor must be securely installed.

Route ribbed belt as follows

Scheme 252

1. Idler roller
2. Vibration damper
3. Coolant pump
4. Tensioning roller
5. Generator
6. Idler roller
7. A/C Compressor

Hold tensioner with open end wrench and remove T10060 A.

Release tensioner.

Check whether ribbed belt is routed correctly.

Start engine and check whether ribbed belt runs correctly.

RIBBED BELT TENSIONER

Removing

Remove ribbed belt. Refer to RIBBED BELT .

Note. The tensioner is not locked.

Remove bolt -arrow- and remove ribbed belt tensioner.

Scheme 253

Installing

1. Tightening specifications, refer to «RIBBED BELT DRIVE COMPONENT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe) .

Installation is in reverse order of removal, note the following

Install ribbed belt. Refer to RIBBED BELT .

ACCESSORY ASSEMBLY BRACKET

Removing

Remove ribbed belt. Refer to RIBBED BELT .

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

Remove A/C compressor from engine. Refer to REMOVAL AND INSTALLATION and tie up to body with A/C lines attached.

Spray rubber nubs -2 and 4- on after-run coolant pump -V51- retainer -1- with silicone-free lubricating spray.

Scheme 254

Disengage rubber nubs from retainer -3- for after-run coolant pump -V51-.

Note. Leave after-run coolant pump -V51- with connected coolant hoses on engine.

Remove bolts -1 to 5- and remove accessory assembly bracket.

Note. Ignore -arrow-.

Installing

1. Tightening specifications, refer to «RIBBED BELT DRIVE COMPONENT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe) .

Installation is in reverse order of removal, note the following

Tighten accessory assembly bracket bolts. (Scheme 237)

Engage nubs -2- and -4- on after-run coolant pump -V51- elastic retainer in bracket -3-.

Install A/C compressor. Refer to REMOVAL AND INSTALLATION .

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

Install ribbed belt. Refer to RIBBED BELT .

VIBRATION DAMPER

Special tools and workshop equipment required

1. Locking Pin T10060 A
2. Counter-Holder Tool T10069

Removing

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

Secure tensioner with T10060 A.

Remove noise insulation in center by loosening mounting parts -1 through 4-.

Scheme 255

Remove left and right noise insulation -arrows-.

Scheme 256

Remove ribbed belt from vibration damper ribbed belt pulley.

Remove vibration damper bolt using T10069.

Scheme 257

Installing

1. Tightening specifications, refer to «RIBBED BELT DRIVE COMPONENT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe) .

Installation is in reverse order of removal, note the following

Install ribbed belt. Refer to RIBBED BELT .

SEALING FLANGE

Special tools and workshop equipment required

1. Assembly Tool T10215
2. Hand drill with plastic brush attachment
3. Protective eyewear
4. Sealant.

Removing

Remove vibration damper. Refer to VIBRATION DAMPER .

Remove bolts -1 to 11-.

Carefully pry up sealing flange.

Installing

1. Tightening specifications (Scheme 238)

Installation is in reverse order of removal, note the following

Carefully remove sealant residue on cylinder block and oil pan.

Scheme 258

Remove sealant residue on sealant flange, for example with a rotating plastic brush.

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

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

Scheme 259

Apply a thin bead of sealant -arrows- on edge between cylinder block and oil pan.

Scheme 260

Lightly coat lower sealing surface -shaded- on sealing flange with sealant.

Scheme 261

Apply sealant bead -arrow- to clean sealing flange sealing surface as shown in illustration.

Scheme 262

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

Note. Sealing flange must be installed within 5 minutes of applying sealant.

Carefully slide sealing flange onto guide pins -arrows- on cylinder block using T10215.

Scheme 263

Install sealing flange. (Scheme 238)

Install vibration damper. Refer to VIBRATION DAMPER .

Install ribbed belt. Refer to RIBBED BELT .

DUAL MASS FLYWHEEL

Special tools and workshop equipment required

1. Counter-Holder Tool T10069

Removing

1. Transmission removed.

Mark dual mass flywheel position to crankshaft for reinstallation.

Scheme 264

Remove dual mass flywheel by counterholding on vibration damper bolt with T10069.

Installing

1. Tightening specifications, refer to «DUAL-MASS FLYWHEEL COMPONENT OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-crankshaft-cylinder-block-engine-codes-cbra-coupe__dual-mass-flywheel-component-overview) .

Installation is in reverse order or removal.

NEEDLE BEARING ON CRANKSHAFT

Special tools and workshop equipment required

1. Drift VW 207 C or Centering Mandrel 3176
2. Kukko 21/1 internal puller
3. 4- Kukko 22/1 counter-support
4. Depth gauge

Removing

1. Transmission removed.

Remove needle bearing with Kukko 21/1 internal puller and Kukko 22/1 counter-support.

Scheme 265

Installing

Drive in needle bearing using VW 207 C or 3176.

Scheme 266

Needle bearing location

Scheme 267

1. Labeled side must be legible on installed needle bearing.
2. Dimension -a- = 2.0 mm.

CRANKSHAFT SEAL, REPLACING

Special tools and workshop equipment required

1. Assembly Tool T10122
2. Pulling Hook T20143

Procedure

1. Transmission removed.

Remove dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

Pry out sealing ring with T20143/2.

Scheme 268

Clean running and sealing surface.

Note. Do not lubricate sealing ring before pressing in.

Slide new sealing ring -A- over T10122/1 onto T10122/2.

Scheme 269

1. Installation position: Closed side faces toward fitting sleeve.

Separate fitting sleeve and guide sleeve.

Place T10122/2 with sealing ring onto crankshaft.

Scheme 270

Press sealing ring in evenly all around with thrust piece T10122/3 until flush.

Scheme 271

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

Install dual mass flywheel. Refer to DUAL MASS FLYWHEEL .

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

1. Dial Gauge Holder VW 387
2. Dial Gauge VAS 6079
3. Locking Pin T10060 A
4. Counter-Holder Tool T10069
5. Assembly Tool T10215
6. Drift VW 207 C or Centering Mandrel 3176
7. 1- Kukko 21/1 internal puller
8. Assembly Tool T10122
9. Pulling Hook T20143

See also:
• COOLANT PUMP
• [For transmission(s) 02E] Removal and Installation
• REMOVAL AND INSTALLATION
• ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER
• TIMING CHAIN COVERS ASSEMBLY OVERVIEW
• RIBBED BELT
• VIBRATION DAMPER
• RIBBED BELT TENSIONER
• ACCESSORY ASSEMBLY BRACKET
• DUAL MASS FLYWHEEL
• CRANKSHAFT SEAL, REPLACING
• PISTON AND CYLINDER DIMENSIONS
• CRANKSHAFT, MEASURING AXIAL PLAY
• CRANKSHAFT, MEASURING RADIAL PLAY
• CRANKSHAFT DIMENSIONS
• CONNECTING ROD, MEASURING AXIAL CLEARANCE
• CONNECTING ROD, MEASURING RADIAL CLEARANCE
• RIBBED BELT DRIVE COMPONENT OVERVIEW
• DUAL-MASS FLYWHEEL COMPONENT OVERVIEW