Audi Workshop Service and Repair Manuals

Renewing sealing flange (pulley end) Special tools and workshop equipment required

t  Assembly sleeve -T03004- t  Electric drill with plastic brush t  Safety goggles t  Sealant → Electronic parts catalogue

Procedure l  Tightening torques → Fig. „„Sealing flange (pulley end) - tightening torque and sequence““ –  Remove vibration damper → Chapter. –  Remove bolts -1- and -2-. –  Release hose clips -arrows- and remove air pipe.

–  Remove bolts -arrows-. –  Carefully release sealing flange from bonded joint.   Note Renew sealing flange.   Caution Make sure sealant residue does not enter lubrication system. Cover open area of cylinder block with a cloth.   WARNING Protect eyes against injuries. Wear safety goggles. –  Use e.g. rotating plastic brush to remove sealant residue on cylinder block. –  Clean sealing surfaces and crankshaft journal; they must be free of oil and grease.   Note Do not additionally oil or grease sealing lip of oil seal in sealing flange.

Caution Risk of damage to oil seal in sealing flange. To make sure sealing lip of oil seal is folded over when installing, the following procedures must be performed. –  Open out sealing lip of oil seal in sealing flange using assembly sleeve -T03004- as shown in illustration. l  Small diameter faces oil seal.

–  Detach assembly sleeve -T03004- after a short while, turn over and insert in oil seal again. l  Large diameter faces oil seal. l  Assembly sleeve -T03004- must protrude by distance -a- at inside of flange l  Distance -a- = approx. 3 mm.   Note

Note the use-by date of the sealant. –  Cut off nozzle of tube at front marking (nozzle Ø approx. 2 mm).

Caution Make sure lubrication system is not clogged by excess sealant. The bead of sealant must not be thicker than specified. –  Apply bead of sealant -A- onto clean sealing surface of sealing flange as shown in illustration. l  Width of sealant bead: 2.5 ... 3 mm l  The bead of sealant must project approx. 1.0 mm above the sealing surface.   Note The sealing flange must be installed within 5 minutes after applying the sealant.

–  Use assembly sleeve -T03004- to carefully fit sealing flange onto crankshaft journal and press onto cylinder block evenly (note centring collar on left and right).

–  Tighten sealing flange → Fig.. –  Install air pipe → Chapter. –  Install vibration damper → Chapter.