Audi 5000 Sedan 5-Cylinder Repair & Service Manual 1977-1983

CRANKSHAFT | REMOVING AND REFITTING

1. With the crankcase upside down on the bench and having removed the pistons, the oil pump (Section 40) and the crankcase rear oil seal flange, check that the crankshaft bearing caps have their numbers stamped on them (photo) and if not, number them, starting at the front of the engine.



2. Remove the bolts from each bearing cap in turn, then remove the caps and lift out the crankshaft.



3. If the bearings are not being replaced, ensure that each half-bearing is identified, so that it is put back in the same place from where it was removed.



4. If the engine has done a high mileage and it is suspected that the crankshaft requires attention, it is best to seek the opinion of a VW/Audi dealer, or a crankshaft refinishing specialist, for advice on the need for regrinding.



5. Unless the bearing shells are known to be almost new, it is worth fitting a new set when the crankshaft is removed. Clean the crankcase webs and bearing caps thoroughly and fit the bearing shells so that the tang on the bearing engages in the recess in the crankcase web, or bearing cap.
   
   Note that the bearing shells for the crankcase webs are different from those for the bearing caps, in that the ones for the webs have an oil hole drilled in them, but the ones for the bearing caps do not (see photo). Also note that the shells of No 4 bearings are different from all the others by being flanged to act as a thrust bearing.



6. Fit the bearing shells so that the ends of the bearing are flush with the joint face. For the lower bearing shells, ensure that the oil hole in the bearing face coincides with the drilling in the crankcase (see photo).



7. Lubricate the crankcase web half-bearings, lubricate the crankshaft journals and lay the crankshaft in its bearings. Lubricate the bearing caps and lay them in their correct position and the correct way round (Fig. 1.112).



8. Fit the bolts to the bearing caps and tighten the bolts of No 4 cap to the specified torque, then check that the crankshaft rotates freely. If it is difficult to rotate the crankshaft, check that the bearing shells are seated properly and that the bearing cap is the correct way round.
   
   Rotation will only be difficult if something is incorrect and the fault must be found. Dirt on the back of a bearing shell can cause tightness in a bearing.



9. Working out from No 4, tighten the remaining bearing caps in turn, checking that the crankshaft rotates freely after each bearing has been tightened.



10. Check that the endplay of the crankshaft is within specification, by inserting feeler gauges between the crankshaft and the thrust face of No 4 bearing (see Fig. 1.46) and levering the crankshaft first in one direction and then the other.



11. The remainder of the operations are a reversal of the removal operations.



12. The rear end of the crankshaft carries a needle roller bearing which supports the front end of the gearbox input shaft.



13. Inspect the bearing for obvious signs of wear and damage. If the gearbox has been removed and dismantled, fit the input shaft into the bearing to see if there is excessive clearance.



14. If the bearing requires replacing, insert a hook in the bearing and pull it out of the end of the shaft.



15. Press in a new bearing, with the lettering on the end of the bearing outwards. Press the bearing in until the end of the bearing is 5.5mm (0.217 in) below the face of the flywheel flange. Installation is similar to that for the 1.6L engine (Fig. 1.47).

GENERAL DESCRIPTION

The body is of unit construction, welded to a frame/floor assembly. It is treated with zinc phosphate and primed by electrocoating to give it good corrosion resistance and the underside and wheel arches are coated with PVC to give protection against flying stones.

A special anti-corrosion treatment is applied to the body cavities and the engine hood panels are treated to give extra protection.

The body has been aerodynamically designed to give low drag and a novel feature of body design gives a high degree of protection against impact.

This protection is achieved by incorporating square suction tubes into each side of the body at the front and the rear. On impact these tubes crumple in accordion pleats absorbing a large amount of impact energy.

There are three basic body styles, the 2-door and 4-door saloons and the 5-door Avant. There is a range of trim options and a choice of refinements such as a sun roof, central door locking, air conditioning and cruise control.

• Introduction: Vehicle identification numbers; Buying parts; Maintenance techniques, and more
• Tune-up and routine maintenance
• Engine and overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams