Audi Workshop Service and Repair Manuals

Removing and installing sealing flange (front) Special tools and workshop equipment required

t  Fitting sleeves -3202-

t  Fitting sleeve -3265- t  Drip tray t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Parts catalogue

Removing –  Remove toothed belt → Chapter. –  Unscrew central bolt -1- for crankshaft sprocket -2-. –  Detach toothed belt sprocket. –  Remove sump (bottom section) → Chapter.

–  Place a drip tray underneath. –  Unbolt brackets -arrows- for oil supply pipes and pull off long oil supply pipe from below.

–  Unscrew 4 bolts -arrows- from sump (top section).

–  Remove idler roller -2-, tensioning roller -1-, tensioning lever -4- and tensioner -3-.

–  Remove bolts -1- and -2-. –  Pull off sealing flange (front). –  Drive out oil seal with flange removed. Installing Installation is carried out in the reverse order; note the following:   Note Renew O-rings. –  Remove sealant residue from front part of sump (top section) and, if necessary, from cylinder block.

–  Remove sealant residue on sealing flange using rotating plastic brush or similar.   WARNING Wear safety goggles. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off nozzle of tube at front marking (Ø of nozzle approx. 3 mm).

–  Attach gasket to dowel pins on sealing surface -A-.   Note Do not apply sealant to sealing surface -A- on cylinder block. –  After attaching gasket, apply a small sealant bead in each case at edges between arrows on left and right.   Note The sealing flange must be installed within 5 minutes after applying sealant.

–  Apply the bead of sealant onto the clean sealing surface of the sealing flange as illustrated. l  Width of sealant bead -arrows-: 2 ... 3 mm.   Note t  The bead of sealant must not be thicker than specified, otherwise excess sealant can enter the sump and obstruct the strainer in the oil intake pipe. t  For fitting sealing flange with oil seal in position, attach fitting sleeve -3202/1- to end of crankshaft.

–  Pre-tighten 4 bolts -arrows- so that they are finger-tight.

–  Insert bolt -2- with locking fluid; Locking fluid → Parts catalogue. –  Tighten bolts -1- to 10 Nm and bolt -2- to 30 Nm.

–  Tighten the 4 bolts -arrows- fully. –  Install sump (bottom section) → Chapter.

–  Do not lubricate sealing lip and outer circumference of oil seal before pressing in. –  Fit oil seal using fitting sleeve -3202/1-. –  Press in seal until flush using fitting sleeve -3265- and central bolt.

–  Install components in the specified sequence: 1 -  Toothed belt tensioner -item 3- 2 -  Tensioning lever -item 4- 3 -  Toothed belt tensioning roller -item 1- 4 -  Idler roller -item 2- –  Pay attention to shims beneath tensioning roller and tensioning lever.

–  Fit crankshaft toothed belt sprocket -2- with new central bolt -1-.   Note t  Contact surface between toothed belt sprocket and crankshaft must be free of oil. t  Do not additionally lubricate bolt for crankshaft toothed belt sprocket. –  Install toothed belt (adjust valve timing) → Anchor. Tightening torques

Component		Nm
Brackets for oil pipes to sump (top section)		10
Sealing flange (front)	M6	10
to cylinder block	M8	30 → Note
Sealing flange (front) to sump (top section)		16
Toothed belt sprocket to crankshaft		200 + 180° → Note → Note
Tensioner to sealing flange (front)		10
Tensioning lever to sealing flange (front)		22
Tensioning roller to sealing flange (front)		22
Idler roller to sealing flange (front)		43

1)  Install using locking fluid; locking fluid → Parts catalogue. 2)  Renew bolt. 3)  180° = one half turn.