Crankshaft, Cylinder Block

2010 Audi A4 2.
0T
ENGINE 2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CAEB (Avant)
ENGINE
2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CAEB (Avant)
CRANKSHAFT, CYLINDER BLOCK

DESCRIPTION AND OPERATION
RIBBED BELT DRIVE AND AUXILIARY COMPONENT BRACKET OVERVIEW
Fig. 1: Ribbed Belt Drive And Auxiliary Component Bracket Overview

Courtesy of AUDI OF AMERICA, LLC
domingo, 7 de junio de 2020 11:39:25

11:39:16 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
2010 Audi A4 2.0T
1. Ribbed Belt
l Check for wear
l Do not kink
l Ribbed belt routing, refer to Fig. 3
CAUTION: Risk of destroying due to reversed running direction on a used

ribbed belt.
l Before removing ribbed belt, marking running direction

with chalk or felt-tip pen for reinstallation later.
l Removing and installing, refer to RIBBED BELT

l When installing, make sure it is seated correctly on the pulleys
2. Idler Roller
l 20 Nm
3. Bolt
l 150 Nm + 90° turn
l Replace
l Coat the O-ring with oil
l Use counter hold tool T10355 to loosen and tighten
CAUTION: The engine could be destroyed.
l Do not turn the crankshaft when a bolt is removed because

this will offset the timing.
4. O-ring
l No replacement part, part of the bolt delivery package
5. Vibration Damper
l With ribbed belt pulley
l Removing and installing, refer to VIBRATION DAMPER
l 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
l
7. Ribbed Belt Tensioning Damper
domingo, 7 de junio de 2020 11:39:16 p. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
2010 Audi A4 2.0T
l To release tension on ribbed belt, pivot using a wrench.

l Secure it with locking tool T40098
l Removing and installing, refer to RIBBED BELT TENSIONING DAMPER
8. Bracket for Assemblies

l With oil filter and engine oil cooler
l Accessory assembly bracket, removing and installing, refer to ACCESSORY ASSEMBLY

BRACKET
l For removing and installing engine oil cooler, refer to ENGINE OIL COOLER
9. Generator
l Removing and installing, refer to Removal and Installation
10. Bolt
l Tightening specifications, refer to Specifications
11. Bolt
l Tightening sequence, refer to Fig. 2
12. Bolt
13. Sleeve
14. Power Steering Pump
15. Air Conditioning (A/C) Compressor

l Do not remove or disconnect refrigerant lines
16. Bolt
l Tightening specifications, refer to Description and Operation
17. Alignment Bushing

l For air conditioning compressor
18. Bolt
2010 Audi A4 2.0T
Fig. 2: 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:
-- Tighten bolts by hand.-- Tighten the bolts to 20 Nm.-- Tighten the bolts an additional 90°.
2010 Audi A4 2.0T
Fig. 3: Ribbed Belt Routing

1. Vibration damper
2. Idler roller
3. Ribbed belt tensioning damper
4. Generator
5. Power steering pump
6. A/C compressor
SEALING FLANGE AND DRIVE PLATE OVERVIEW
2010 Audi A4 2.0T
Fig. 4: Sealing Flange And Drive Plate Overview

1. Cylinder Block
2. Sealing Flange with Seal
l Replace, refer to SEALING FLANGE, TRANSMISSION SIDE
l Do not oil or grease the sealing lip of seal
l Before installing, remove oil remains from crankshaft journal with a clean cloth
3. Bolt
l Tightening sequence with 8 bolts, refer to Fig. 5
l Tightening sequence with 6 bolts, refer to Fig. 6
4. Drive Plate
2010 Audi A4 2.0T
l To loosen the bolts, secure with 3067

5. Bolt
l60 Nm + 90° turn
l Replace
6. Needle Bearing
l For removing and installing the needle bearing, refer to NEEDLE BEARING ON DRIVE
PLATE, MANUAL TRANSMISSION
7. Intermediate Plate
l Must be located on dowel sleeves
l Be careful not to damage or bend when installing
l Is hooked in at sealing flange, refer to Fig. 7
8. Alignment Sleeve
l Quantity: 2
Fig. 5: Identifying Sealing Flange Tightening Sequence

-- Tighten bolts -1 through 8- in the sequence shown:
-- 1. Tighten the bolts hand-tight.
-- 2. Tighten the bolts to 9 Nm.
2010 Audi A4 2.0T
Fig. 6: Transmission Side Sealing Flange - Tightening Sequence, With 6 Bolts

-- Tighten new bolts -1 through 6- in the sequence shown:
-- 2. Tighten the bolts to 4 Nm + 45°.
NOTE: Only 6 bolts are installed, 2 bolt openings remain open.
Fig. 7: Identifying Intermediate Plate Alignment Bushings

2010 Audi A4 2.0T
-- 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 .
Fig. 8: Crankshaft Assembly Overview

1. Cylinder Block
2. Bearing Shell for Cylinder Block
2010 Audi A4 2.0T
l With lubricating groove

l Lubricate
l Do not interchange used bearing shells (mark)
l Crankshaft bearing shells identification (classification), refer to ALLOCATION OF THE

CRANKSHAFT BEARING SHELLS (CLASSING)
3. Crankshaft
l After removal, lay aside so that sensor wheel, refer to item 8 is not rested on and becomes damaged
l 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)
l Axial clearance, refer to CRANKSHAFT, MEASURING AXIAL CLEARANCE
l Radial clearance, refer to CRANKSHAFT, MEASURING RADIAL PLAY
l Do not turn crankshaft when measuring radial play
l Crankshaft dimensions, refer to CRANKSHAFT DIMENSIONS
4. Bearing Shell for Bearing Cap

l Without lubricating groove
l Lubricate
l Crankshaft bearing shells identification (classification), refer to ALLOCATION OF THE

CRANKSHAFT BEARING SHELLS (CLASSING)
5. Bolt
l Replace
6. Bearing Cap
l Bearing cap 1: Belt pulley side
l Retaining tabs of bearing shells and cylinder block/bearing caps must lie above one another
7. Bolt
l 10 Nm + 90° turn
l Replace
l Replace sensor wheel every time bolts are loosened, refer to SENSOR WHEEL
8. Sensor Wheel
l For Engine Speed (RPM) sensor -G28-
l Only possible to install in one position - Bores are offset
l Replace sensor wheel every time bolts are loosened
l Removing and installing, refer to SENSOR WHEEL
9. Thrust Washers
l Lubricate
l For bearing 3
10. Bolt
2010 Audi A4 2.0T
l Replace
Fig. 9: Crankshaft Bearing Cap, Installing

-- 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
2010 Audi A4 2.0T
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.
Fig. 10: Locating Cylinder Block Identification On Top (Transmission Side) Of

Cylinder Block
The identification on the cylinder block is for the upper bearing shell.
2010 Audi A4 2.0T
Fig. 11: Locating Identification On Cylinder Block

-- Note the letters and then match it to the color identification in the table.
Bearing Cap Bearing Shell Identification:
2010 Audi A4 2.0T
Fig. 12: Locating Identification On Crankshaft

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.
S = Black
R = Red
G = Yellow
B = Blue
W = White
PISTON AND CONNECTING ROD OVERVIEW
2010 Audi A4 2.0T
Fig. 13: Identifying Assembly Overview: Pistons And Connecting Rod

1. Connecting Rod Bolt

l 45 Nm + 90° turn
l Replace
l Lubricate the threads and contact surface
l Use old bolt to measure radial play
l Tighten to 30 Nm to measure radial play, do not turn further
2. Connecting Rod Bearing Cap

l Pay attention to the installed position
l Due to the separation procedure (cracking) of the connecting rod, the connecting rod bearing cap
2010 Audi A4 2.0T
only fits in one position and only to the corresponding connecting rod.
l Mark affiliation to cylinder -A-
l Installation position: Markings -B- point to belt pulley side
l Separate new connecting rod, refer to NEW CONNECTING ROD, SEPARATING
3. Bearing Shells
l Installed location, refer to Fig. 14
l Axial play new: 0.10 to 0.35 mm; Wear limit: 0.40 mm
l 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
l 27 Nm
5. Oil Spray Jet

l For piston cooling
l Do not bend the oil injector jet
l Replace the oil spry nozzles if they are bent
6. Circlip
l Replace
7. Piston Pin
8. Piston
l Removing and installing, refer to PISTON
l Mark installed position and cylinder allocation
l Arrow on piston face points toward belt pulley side
l Pistons and cylinder bore, checking, refer to PISTONS AND CYLINDER BORE, CHECKING
9. Compression Rings
l Use commercially available piston ring pliers for removing and installing
l Offset gaps by 120°
l Installed position: Identification "TOP" or "R" towards piston crown
l Checking ring gap, refer to Fig. 23
l Check piston ring groove clearance, refer to Fig. 24
10. Oil Scraping Ring

l 2-part
l Install offset gaps by 120° to the neighboring compression ring
l The "TOP" or "R" marking must face toward the piston crown.
l Checking ring gap, refer to Fig. 23
l Side clearance cannot be measured.
11. Connecting Rod

l Only replace as set
2010 Audi A4 2.0T
l Mark affiliation to cylinder -A-

l Installation position: Markings -B- point to belt pulley side
l Separate new connecting rod, refer to NEW CONNECTING ROD, SEPARATING
l Radial clearance, measuring, refer to CONNECTING ROD, MEASURING RADIAL
CLEARANCE
Fig. 14: Dimension -A- Must Be Same At Left And Right

-- 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.
2010 Audi A4 2.0T
Fig. 15: Clamping Connecting Rod In Vise Equipped With Aluminum Protective Pads
NOTE: l Only clamp the connecting rod lightly to avoid damaging it.
l 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.
Fig. 16: Carefully Taping Against Connecting Rod Bearing Cap

2010 Audi A4 2.0T
SPECIFICATIONS
CRANKSHAFT DIMENSIONS
(Dimensions in mm)
Crankshaft Bearing Pin Connecting Rod Bearing Pin

Reconditioning Dimension (1) Diameter Diameter
Basic dimension 58.00 47.80
(1) The preparation of worn crankshafts is not provided.
FASTENER TIGHTENING SPECIFICATIONS
Component Bolt Size Nm

Connecting rod bearing cap 1 - 45 + 90°
Drive plate 1 - 60 + 90°
Idler roller - 20
Pressure relief valve - 27
Sensor wheel 1 - 10 + 90°
Ribbed belt tensioning damper - 40
Vibration damper 1 - 150 + 90°
l
1 Always replace
Accessory Assembly Bracket Tightening Sequence
-- Mount the accessory assembly bracket and then mount the bolts -4-.
2010 Audi A4 2.0T

-- Tighten bolts in 3 stages in -1 to 5- sequence as follows:
-- Tighten bolts by hand.-- Tighten the bolts to 20 Nm.-- Tighten the bolts an additional 90°.
Transmission Side Sealing Flange - Tightening Sequence, with 8 Bolts
2010 Audi A4 2.0T

-- Tighten bolts -1 through 8- in the sequence shown:
-- 2. Tighten the bolts to 9 Nm.
Transmission Side Sealing Flange - Tightening Sequence, with 6 Bolts
Fig. 19: Transmission Side Sealing Flange - Tightening Sequence, With 6 Bolts
2010 Audi A4 2.0T
-- Tighten new bolts -1 through 6- in the sequence shown:
-- 2. Tighten the bolts to 4 Nm + 45°.
Crankshaft, Tightening Sequence
-- Tighten the crankshaft bolts in the sequence -1 to 5-.
Fig. 20: Crankshaft Bearing Cap, Installing

-- 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.
2010 Audi A4 2.0T
-- Tighten the bolts -arrows- 90° further using a rigid wrench.
DIAGNOSIS AND TESTING
CRANKSHAFT, MEASURING AXIAL CLEARANCE
Special tools and workshop equipment required
l Dial Gauge Holder VW 387

l 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.
Fig. 21: Attaching Dial Indicator Together With VW387 Dial Gauge Holder To Cylinder Block And Set
Indicator Against Crankshaft Counterweight
-- Press crankshaft by hand against gauge and set gauge to "0".
-- Press crankshaft off gauge and read value.
Axial clearance:
l New: 0.070 to 0.231 mm

l Wear limit: 0.30 mm
CRANKSHAFT, MEASURING RADIAL PLAY
2010 Audi A4 2.0T
l Plastigage
Procedure
NOTE: l Do not interchange used bearings

l 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.
l 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:
l New: 0.017 to 0.037 mm

l Wear limit: 0.15 mm
PISTONS AND CYLINDER BORE, CHECKING
Fig. 22: Checking Piston

2010 Audi A4 2.0T
-- 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.
l Deviation from nominal size: max. 0.04 mm.
Piston Diameter
Basic dimension mm 82.465 1)
l
1) Measurements without graphite coating (thickness = 0.02 mm). The graphite coating wears off.
Fig. 23: Checking Piston Ring Gap

-- 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.
Piston Ring Dimensions in mm New Wear Limit

Compression ring 0.20 to 0.40 0.80
Oil scraping ring 0.25 to 0.50 0.80
2010 Audi A4 2.0T
Fig. 24: Checking Piston Ring Gap

-- Clean piston ring groove.
-- Measure with feeler gauge.
Piston Ring
Dimensions New Wear Limit
in mm
1st
Compression 0.06 to 0.09 0.20
ring
2nd
Compression 0.03 to 0.06 0.15
ring
Oil scraping
Cannot be measured
rings
2010 Audi A4 2.0T
Fig. 25: Checking Cylinder Bores

l Internal dial gauge VAS 6078 or

l Inside Micrometer Set 18-100 mm US1033/S
l Engine and Transmission Holder VAS 6095
NOTE: l 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.
l Always measure the cylinder bore in 3 places laterally and longitudinally
using VAS 6078 or US1033/S.
CAUTION: Do not bore, hone, grind or rework the cylinder bores with shop tools.
Reworking damages the surface of the cylinder bore.
-- Using a VAS 6078 or US1033/S measure in a diagonal sequence at 3 positions transversely -A- and
longitudinally -B-.
2010 Audi A4 2.0T
l Deviation from nominal size: max. 0.08 mm.
Cylinder Bore Diameter

Basic dimension mm 82.51
NOTE: Measurement of cylinder bore may not be performed when the cylinder block is
mounted in engine and transmission holder VAS 6095, false measurements are
possible.
CONNECTING ROD, MEASURING RADIAL CLEARANCE
l 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:
l New: 0.02 to 0.06 mm.

l Wear limit: 0.09 mm.
-- Replace connecting rod bolts.
REMOVAL AND INSTALLATION
RIBBED BELT
l Locking Tool T40098
Removing
2010 Audi A4 2.0T
CAUTION: Risk of destroying due to reversed running direction on a used ribbed belt.
l Before removing ribbed belt, marking running direction with chalk or

felt-tip pen for reinstallation later.
-- To release ribbed belt tension, rotate tensioner in direction of -arrow-.
Fig. 26: Release Ribbed Belt Tension, Rotate Tensioner In Direction Of Arrow
-- 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.
2010 Audi A4 2.0T
Fig. 27: Ribbed Belt Routing

-- 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.
2010 Audi A4 2.0T
RIBBED BELT TENSIONING DAMPER
Removing

-- Remove the ribbed belt from the tensioner.
-- Remove the bolt -1- and remove the ribbed belt tensioner from the accessory assembly bracket.
Installing
l Tightening specifications, refer to RIBBED BELT DRIVE AND AUXILIARY COMPONENT

BRACKET OVERVIEW.
2010 Audi A4 2.0T
-- Install the ribbed belt. Refer to RIBBED BELT.
ACCESSORY ASSEMBLY BRACKET
l Drip Tray for VAS 6100 VAS 6208

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

-- Remove ribbed belt.
-- Remove the bolt -1- and remove the ribbed belt tensioner from the accessory assembly bracket.
2010 Audi A4 2.0T
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-.
Fig. 31: Oil Pressure Switch

-- Loosen the hose clamps -arrows- and remove the air guide hose.
Fig. 32: Loosen Hose Clamps
2010 Audi A4 2.0T
-- Remove generator. Refer to Removal and Installation .
-- Disconnect solenoid clutch electrical connector -1- on Air Conditioning (A/C) compressor.
Fig. 33: A/C Compressor Bolts And Solenoid Clutch Electrical Connector
WARNING: Refrigerant can cause serious personal injury.
l Do not open the air conditioning refrigerant circuit.
-- Remove A/C compressor bolts -arrows-.
CAUTION: Risk of damaging refrigerant lines and hoses.
l Do not stretch, kink or bend refrigerant lines and hoses.
-- 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.
2010 Audi A4 2.0T
Fig. 34: Identifying Power Steering Pump

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.
Fig. 35: Identifying Oil Filter

2010 Audi A4 2.0T
-- 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

BRACKET OVERVIEW.
NOTE: l Replace bolts which have been tightened to an additional torque.

l Replace the O-rings and seals.
-- Coat the O-rings -4- with coolant additive.
2010 Audi A4 2.0T
Fig. 37: Accessory Assembly Bracket, Coolant Pump Housing, Connection And O-Rings
-- 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. Refer to Fig. 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 .
-- Fill with coolant. Refer to COOLANT, DRAINING AND FILLING => Filling .
-- Check the oil level.
VIBRATION DAMPER

l Counter Hold Tool T10355
Removing
-- Remove the front noise insulation. Refer to Description and Operation .
2010 Audi A4 2.0T
-- Remove the coolant fan electrical connector -1- from the bracket and disconnect it by sliding the retainer back
-arrow- and pressing the release down.
Fig. 38: Remove Coolant Fan Electrical Connector

-- Free up the electrical wiring harness to the radiator fan control module.
-- Disconnect electrical connectors -2 and 3- -3-.
Fig. 39: Disconnect Electrical Connectors

2010 Audi A4 2.0T
-- Remove the bolt -arrow- and the coolant fan control module -1-.

-- Remove the ribbed belt from the vibration damper ribbed belt pulley.
-- Rotate the vibration damper using the T10355 into the "OT" position -arrow-.
2010 Audi A4 2.0T
Fig. 41: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355
l 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.
l 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.
Installing

BRACKET OVERVIEW.
NOTE: l Replace the vibration damper bolt with an O-ring.

l The O-ring -1- is supplied with the bolt. Coat it with oil before installing.
2010 Audi A4 2.0T
Fig. 42: Identifying O-Ring And Tooth Contour

-- Coat the sealing lip with engine oil.
-- Mount the vibration damper; when doing this, pay attention to the tooth contour -arrow-.
-- Install the radiator fan control module -J293-. Refer to RADIATOR FAN CONTROL MODULE .
DRIVE PLATE
l Counter Hold Tool 10 - 201
Removing
l Transmission removed.
-- Insert the 10 - 201 to loosen the bolts.
2010 Audi A4 2.0T
Fig. 43: Drive Plate Overview

CAUTION: The outer surface of the bearing flange at the drive plate could be
damaged.
l Use a multipoint socket wrench with a shaft at least 40 mm long to

loosen and tighten the drive plate bolts.
-- Remove the bolts, drive plate and sensor wheel.
Installing
l Tightening specifications, refer to SEALING FLANGE AND DRIVE PLATE OVERVIEW.
NOTE: l Replace the drive plate bolts.

l 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
2010 Audi A4 2.0T
l Tube 31.5 mm Dia. VW 418 A

l Tube 28 mm Dia. 100 mm VW 421
l Sleeve 40 - 103
Procedure
-- Remove the drive plate. Refer to DRIVE PLATE.
-- Place the 40 - 103 under the drive plate to remove and install.
Fig. 44: Removing Drive Plate

-- Press the bearing sleeve out using the VW 421 and shop press.
l 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.
2010 Audi A4 2.0T
Fig. 45: Removing Drive Plate

l Installation position: the closed side of the needle bearing faces the engine.
-- Installing drive plate. Refer to DRIVE PLATE.
SEALING FLANGE, TRANSMISSION SIDE
l Guide Sleeve T20097

l Hand drill with plastic brush attachment
l Protective goggles
l Sealant
Removing
-- Remove the drive plate. Refer to DRIVE PLATE.
-- Unhook the intermediate plate at sealing flange and at the alignment sleeves -arrows-.
2010 Audi A4 2.0T
Fig. 46: Identifying Intermediate Plate Alignment Bushings

-- Remove the bolts -1 through 8-

NOTE: There may be 6 bolts installed, depending on the version.
-- Remove the transmission side sealing flange.
Installing
2010 Audi A4 2.0T
l For the correct tightening specifications, refer to SEALING FLANGE AND DRIVE PLATE
OVERVIEW.
l Silicone sealant
NOTE: l Note the expiration date of the silicone sealant.

l 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).
Fig. 48: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)
-- Apply the silicone sealant on the clean sealing surface of the new cover as shown in the illustration.
2010 Audi A4 2.0T
Fig. 49: Identifying Silicone Sealant Applied On Cover Sealing Surface

l Thickness of sealant bead: 2 to 3 mm.
NOTE: l The sealing flange must be installed within 5 minutes after application of
silicon sealant.
l 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.
2010 Audi A4 2.0T
Fig. 50: Identifying Guide Sleeve On Crankshaft

-- Slide the sealing flange on the crankshaft flange using the T20097 and tighten the bolts right away, tightening
sequence:
l Cover with 8 bolts, refer to Fig. 5

l Cover with 6 bolts, refer to Fig. 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.
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-.
2010 Audi A4 2.0T
Fig. 51: Identifying Attachment Points, Countersunk Screws, Crankshaft & Sensor Wheel
NOTE: l 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.
l Installation of sensor wheel is only possible in one position - the bores are
offset.
l Tightening specifications, refer to CRANKSHAFT OVERVIEW.
PISTON
l Pilot Drift VW 222 A

l 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:
l Refer to CYLINDER HEAD WITH WRENCH CLEARANCE

l Refer to CYLINDER HEAD WITHOUT WRENCH CLEARANCE
2010 Audi A4 2.0T
-- 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
l Tightening specifications, refer to PISTON AND CONNECTING ROD OVERVIEW.
NOTE: l Replace bolts which have been tightened to an additional torque.

l Arrow on piston face points toward the belt pulley side.
l 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:
l Refer to CYLINDER HEAD WITH WRENCH CLEARANCE

l Refer to CYLINDER HEAD WITHOUT WRENCH CLEARANCE
-- Install the upper oil pan. Refer to UPPER OIL PAN .
SPECIAL TOOLS
2010 Audi A4 2.0T
Fig. 52: Identifying Guide Sleeve T20097

l Dial Gauge Holder VW 387
Fig. 53: Identifying Dial Gauge Holder VW 387

l Dial Gauge 0-10 mm VAS 6079
2010 Audi A4 2.0T
Fig. 54: Identifying Dial Gauge 0-10 mm VAS 6079

Fig. 55: Identifying Locking Tool T40098

l Drip Tray for VAS 6100 VAS 6208
2010 Audi A4 2.0T
Fig. 56: Identifying Drip Tray for VAS 6100 VAS 6208
l Counter Hold Tool T10355
Fig. 57: Identifying Counter Hold Tool T10355

l Counter Hold Tool 10 - 201
2010 Audi A4 2.0T
Fig. 58: Identifying Counter Hold Tool 10 - 201

l Tube 31.5 mm Dia. VW 418 A
Fig. 59: Identifying Tube 31.5 mm Dia. VW 418 A

l Tube 28 mm Dia. 100 mm VW 421
2010 Audi A4 2.0T
Fig. 60: Identifying Tube 28 mm Dia. 100 mm VW 421

l Sleeve 40 - 103
Fig. 61: Identifying Sleeve 40 - 103

l Pilot Drift VW 222 A
2010 Audi A4 2.0T
Fig. 62: Identifying Pilot Drift VW 222 A

l Not illustrated:
l Piston Installation Tool 82.5 mm Bore SET 850

Crankshaft, Cylinder Block

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2010 Audi A4 2.

2.0 Liter - Crankshaft, Cylinder Block - Engine Code(s): CAEB (Avant)

CRANKSHAFT, CYLINDER BLOCK

RIBBED BELT DRIVE AND AUXILIARY COMPONENT BRACKET OVERVIEW

Fig. 1: Ribbed Belt Drive And Auxiliary Component Bracket Overview

domingo, 7 de junio de 2020 11:39:25

l Ribbed belt routing, refer to Fig. 3

CAUTION: Risk of destroying due to reversed running direction on a used

l Before removing ribbed belt, marking running direction

l Removing and installing, refer to RIBBED BELT

l Coat the O-ring with oil

l Use counter hold tool T10355 to loosen and tighten

CAUTION: The engine could be destroyed.

l Do not turn the crankshaft when a bolt is removed because

l Removing and installing, refer to VIBRATION DAMPER

CAUTION: The engine could be destroyed.

l In order not to change the valve timing, the crankshaft

7. Ribbed Belt Tensioning Damper

l To release tension on ribbed belt, pivot using a wrench.

l Removing and installing, refer to RIBBED BELT TENSIONING DAMPER

8. Bracket for Assemblies

l Accessory assembly bracket, removing and installing, refer to ACCESSORY ASSEMBLY

15. Air Conditioning (A/C) Compressor

l Removing and installing, refer to Removal and Installation

17. Alignment Bushing

Fig. 2: Accessory Assembly Bracket Tightening Sequence

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

Fig. 3: Ribbed Belt Routing

SEALING FLANGE AND DRIVE PLATE OVERVIEW

Fig. 4: Sealing Flange And Drive Plate Overview

l Do not oil or grease the sealing lip of seal

l Tightening sequence with 6 bolts, refer to Fig. 6

l To loosen the bolts, secure with 3067

l Be careful not to damage or bend when installing

l Is hooked in at sealing flange, refer to Fig. 7

Fig. 5: Identifying Sealing Flange Tightening Sequence

-- Tighten bolts -1 through 8- in the sequence shown:

-- 1. Tighten the bolts hand-tight.

-- 2. Tighten the bolts to 9 Nm.

Fig. 6: 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°.

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

Fig. 7: Identifying Intermediate Plate Alignment Bushings

Fig. 8: Crankshaft Assembly Overview

l With lubricating groove

l Do not interchange used bearing shells (mark)

l Crankshaft bearing shells identification (classification), refer to ALLOCATION OF THE

l Radial clearance, refer to CRANKSHAFT, MEASURING RADIAL PLAY

l Do not turn crankshaft when measuring radial play

l Crankshaft dimensions, refer to CRANKSHAFT DIMENSIONS

4. Bearing Shell for Bearing Cap

l Do not interchange used bearing shells (mark)

l Crankshaft bearing shells identification (classification), refer to ALLOCATION OF THE

l Tightening sequence, refer to Fig. 9

l Only possible to install in one position - Bores are offset

l Replace sensor wheel every time bolts are loosened

l Removing and installing, refer to SENSOR WHEEL