Audi TT (2007 year). Manual — part 21
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Pulling off spur gear
– Insert thrust piece -T10392/1- in end of crankshaft.
– Insert puller -T10392- in holes in spur gear, turn clockwise
-arrow- and screw in locking pins -A-.
– Counterhold crankshaft with ring spanner -A- and pull spur
gear off end of crankshaft by screwing in spindle with ring
spanner -B-.
Shrink-fitting spur gear
Note
♦
While heating up the new spur gear, monitor the temperature
with the temperature gauge -VAS 6519- .
♦
When the temperature reaches 200 °C, you have approx. 4
seconds to fit the spur gear on the crankshaft.
♦
A higher temperature increases the amount of time available
(220 °C = approx. 6 seconds).
♦
Make sure the end of the crankshaft is clean.
Caution
Do not exceed a maximum temperature of 240 °C; otherwise
the spur gear can become discoloured and distorted.
3. Crankshaft
75
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Place the new spur gear flat on a hotplate (commercially avail‐
able) and heat it to at least 200 °C, but not more than 240 °C.
The lettering must face upwards.
– Set temperature gauge -VAS 6519- to measuring range 2.
– Position temperature sensor -VAS 6519/1- on collar of spur
gear (as shown) and read off temperature at temperature
gauge.
WARNING
Risk of burns. Use suitable protective gloves for the following
steps.
– When the required temperature has been reached, pick up the
spur gear with pliers as illustrated.
Note
Take care not to damage the teeth of the spur gear.
– With the aid of fitting tool -10 - 203- , slide spur gear by hand
onto end of crankshaft as far as stop. This must be done with‐
out delay, taking care to keep the gear straight.
– Wait a few minutes to allow the spur gear to cool down, and
then install the balance shaft assembly.
⇒ “1.6 Installing a new balance shaft assembly”, page 146
⇒ “1.7 Re-installing a used balance shaft assembly”, page 149
76
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4
Pistons and conrods
Note
Oil spray jet and pressure relief valve
4.1
Pistons and conrods - exploded view
1 - Bolt
❑ Renew
❑ Lubricate threads and
contact surface
❑ 30 Nm + 90°
❑ When measuring radial
clearance, tighten used
bolt to 30 Nm but not fur‐
ther
2 - Conrod bearing cap
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod
❑ Mark cylinder allocation
in colour -B-
❑ Installation position:
Markings -A- face to‐
wards pulley end
3 - Bearing shell
❑ Installation position
❑ Mark used bearing
shells for re-installation
but not on bearing sur‐
face
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material. Distin‐
guishing feature on new
bearing shells: black marking on bearing surface near joint
❑ Check that it is securely seated
❑ Axial clearance: wear limit: 0.37 mm
❑ Measuring radial clearance
4 - Conrod
❑ Only renew as a complete set
❑ With industrially cracked conrod bearing cap
❑ Separating parts of new conrod
❑ Mark cylinder allocation in colour -B-
❑ Installation position: Markings -A- face towards pulley end
4. Pistons and conrods
77
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Circlip
❑ Renew
6 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift -VW 222 A-
7 - Piston
❑ With combustion chamber
❑ Version fitted in vehicle may differ from illustration
❑ Mark installation position and cylinder number
❑ Checking
❑ Install using piston ring clamp
❑ Piston and cylinder dimensions
❑ Measuring cylinder bore
❑ Checking piston projection at “TDC”
8 - Piston rings
❑ Compression rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Measuring ring gap
❑ Measuring ring-to-groove clearance
9 - Piston ring
❑ Oil scraper ring
❑ Offset gap 120° from bottom compression ring
❑ Use piston ring pliers to remove and install
❑ Measuring ring gap
❑ Measuring ring-to-groove clearance
Measuring piston ring gap
– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring
new
mm
Wear limit
mm
1st compression ring
0.25 … 0.40
1.00
2nd compression ring
0.25 … 0.40
1.00
Oil scraper ring
0.25 … 0.50
1.00
78
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