Audi Workshop Service and Repair Manuals

Removing and installing sealing flange, pulley end Special tools and workshop equipment required

t  Locking pin -T10060 A-

t  Counterhold tool -T10069-

t  Assembly tool -T10215- for vehicles from 11.2005 onwards t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue

Removing l  Engine in vehicle.   Note Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Turn tensioner in direction of -arrow- to slacken poly V-belt and lock in position with locking pin -T10060 A-.

–  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-. –  Remove poly V-belt from pulley for vibration damper.

–  Unscrew bolt for vibration damper (use counterhold -T10069-).

–  Remove bolts -1 ... 11-. –  Lever off front sealing flange and remove. –  Drive out oil seal with flange removed. Installing l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following:   Note Place a cloth over the exposed section of the sump. –  Carefully remove any sealant residue on the cylinder block and sump.   WARNING Protect eyes against injuries. Wear safety goggles.

–  Remove sealant residue from sealing flange with rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease.

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

–  Apply a thin bead of sealant at the edge of the joint between the cylinder block and the sump -arrows-.

–  Coat the lower sealing surface on the sealing flange lightly with sealant -hatched area-.

–  Apply the bead of sealant onto the clean sealing surface of the sealing flange as illustrated -arrow-. l  Width of sealant bead -arrow-: 2 ... 3 mm.   Note t  Sealant bead must not be wider than 3 mm, otherwise excess sealant could ingress into sump and clog strainer in oil intake pipe. t  The sealing flange must be installed within 5 minutes after applying sealant. Vehicles up to 11.2004: –  Push the sealing flange carefully onto the dowel pins on the cylinder block.   Note Use guide sleeve -T10053/1- to attach sealing flange with oil seal fitted.

Vehicles from 11.2004 onwards: –  Carefully push sealing flange over assembly tool -T10215- onto dowel pins -arrows- on cylinder block.

All vehicles (continued): –  Tighten bolts in three stages as follows:

1.  Screw in bolts -1 ... 11- hand-tight. 2.  Tighten bolts -1 ... 6- in diagonal sequence and in stages to 10 Nm. 3.  Tighten bolts -7 ... 11- to 10 Nm.

Vehicles up to 11.2004: –  Install crankshaft oil seal (pulley end) → Chapter. All vehicles (continued): –  Install vibration damper with new securing bolt → Chapter. –  Install poly V-belt → Chapter.