Audi Workshop Service and Repair Manuals

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

t  Pin wrench -3212- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue Removing –  Drain off coolant → Chapter. –  Move lock carrier to service position → Chapter. –  Remove poly V-belt → Chapter. –  Remove coolant pipe (right-side) → Chapter.

–  Unbolt coolant pump pulley -arrows- (counterhold with pin wrench -3212-). –  Remove vibration damper → Chapter.

–  Pry off cover from idler roller for poly V-belt. –  Unscrew bolt -arrow- and detach idler roller from front sealing flange.

–  Detach noise insulation panel from sealing flange (front) -arrows-.

–  Remove bolts. –  Pull off front sealing flange (right-side first -arrow 1-, then left-side -arrow 2-). –  Drive out oil seal with sealing flange removed. Installing   Note t  Renew gaskets, seals and O-rings. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. –  Remove old sealant from grooves in sealing flange and from sealing surfaces.

WARNING Wear safety goggles. –  Remove remaining sealant from sealing flange and cylinder block/sump (top section) with rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off tube nozzle at front marking (diameter of nozzle approx. 1.5 mm).

–  Install sealing elements -2- and -4- and O-rings -1- and -3-. –  Apply bead of sealant -arrow- onto clean sealing surface of front sealing flange as illustrated. l  The bead of sealant must project 1.5 … 2.0 mm above the sealing surface.   Note t  The sealant bead must not be thicker than specified, otherwise excess sealant could enter the sump and clog the strainer in the oil pump. t  The front sealing flange must be installed within 5 minutes after applying sealant.

–  Tighten bolts securing front sealing flange -arrow- in diagonal sequence and in stages. Remaining installation steps are carried out in reverse sequence; note the following: –  Install crankshaft oil seal (pulley end) → Chapter. –  Install vibration damper → Chapter. –  Install coolant pipe (right-side) → Chapter. –  Install poly V-belt → Chapter. –  Install lock carrier with attachments → Rep. gr.50. –  Install bumper cover (front) → Rep. gr.63. –  Fill cooling system → Anchor. Tightening torques

Component		Nm
Front sealing flange to cylinder block		9
Noise insulation to engine		9
Idler roller to sealing flange		23
Poly V-belt pulley to coolant pump		23
Hose clips	Width 9 mm	3
	Width 13 mm	5.5