Audi Workshop Service and Repair Manuals

Removing and installing sealing flange (front)

Special tools and workshop equipment required

t	Fitting sleeve -3202/1- from fitting sleeves -3202-

t	Fitting sleeve -3265-

t	Used oil collection and extraction unit -V.A.G 1782-

t	Electric drill with plastic brush attachment

t	Safety goggles

t	Sealant → Parts catalogue

Removing –  Remove noise insulation -arrows-. –  Remove front bumper → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50. –  Remove toothed belt → Chapter.

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

–  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Remove bolt -2- (counterhold at welded-on nut). –  Detach cover plate at the points indicated by -arrows-. –  Remove bolts -1- and -3-. –  Pull off the longer of the two oil pipes.

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

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

–  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø).

–  Attach gasket to dowel pins on sealing surface -A-.   Note Do not apply sealant to sealing surface -A- on cylinder block. –  After fitting gasket, apply a small sealant bead in each case to edges between -left arrows- and -right arrows-.

–  Apply sealant bead to clean sealing surface of sealing flange, as shown in illustration. l  Thickness of sealant bead: 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  The sealing flange must be installed within 5 minutes after applying sealant. t  For fitting sealing flange with oil seal in position, attach fitting sleeve -3202/1- to end of crankshaft.

–  Hand-tighten the 4 bolts -arrows-.

–  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. l  M6 - 10 Nm l  M7 - 16 Nm –  Install sump (bottom section) → Anchor.   Note

Do not lubricate sealing lip and outer rim of oil seal before pressing in. –  Push on oil seal using fitting sleeve -3202/1-. –  Press in oil seal until flush using the centre bolt and fitting sleeve -3265-.

–  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. –  Install vibration damper → Chapter. –  Install poly V-belt → Chapter. –  Install viscous fan → Chapter. –  Install lock carrier with attachments → Rep. Gr.50. –  Install front bumper → Rep. Gr.63. Tightening torques

Component		Nm
Brackets for oil pipes to sump (top section)		10
Cover plate to rear cover plate		10
Front sealing flange to cylinder block	M6	10
	M8	30 1)
Sealing flange (front) to sump (top section)	M6	10
	M7	16
Toothed belt sprocket to crankshaft		200 + 180° 2)3)
Toothed belt tensioning roller to sealing flange (front)		42
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
l  1) Install using locking fluid; for locking fluid refer to → Parts catalogue. l  2) Renew bolt. l  3) 180° = one half turn.