Audi Workshop Service and Repair Manuals

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

t  Counterhold tool -3415-

t  Locking pin -T10060 A- or -T10060- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Parts catalogue

Removing –  On vehicles with auxiliary/additional heater, remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-fasteners -1- and -2- and take off front noise insulation. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Move lock carrier into its service position → General body repairs, exterior; Rep. Gr.50.

–  Pull off engine cover panel -arrows-.   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 the tensioner in the direction of the -arrow- to slacken the poly V-belt.

–  Lock tensioner for poly V-belt in position with locking pin -T10060 A- or -T10060-. –  Remove poly V-belt.

–  Unscrew bolt -arrow- and remove idler roller for poly V-belt. –  Remove toothed belt: t  Vehicles to 04.2003 → Chapter. t  Vehicles from 05.2003 to 05.2004 → Chapter. t  Vehicles from 06.2004 → Chapter.

–  Remove crankshaft sprocket; use counterhold -3415- to lock sprocket in place.

–  Remove bolts -1 ... 10-. –  Pull off sealing flange (front). –  Drive out oil seal with sealing flange removed. Installing   Note Place a cloth over the exposed section of the sump. –  Carefully remove any sealant residue on the cylinder block and sump.   WARNING 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. 2 mm Ø).

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

–  Apply the bead of sealant onto the clean sealing surface of the sealing flange as illustrated -arrow-. l  Thickness of sealant bead: 2 ... 3 mm   Note The sealant bead must not be thicker than specified, otherwise excess sealant could enter the sump and clog the strainer in the oil pump.

–  Coat the lower sealing surface on the sealing flange lightly with sealant -hatched area-.   Note The sealing flange must be installed within 5 minutes after applying sealant. –  Push the sealing flange carefully onto the dowel pins on the cylinder block.

–  Tighten bolts in the specified sequence: 1.  Tighten bolts -1 ... 6-. 2.  Tighten bolts -7 ... 10-. –  Install crankshaft oil seal (pulley end) → Chapter.

–  Renew centre bolt for toothed belt sprocket. l  Contact surface between toothed belt sprocket and crankshaft must be free of oil. l  Do not lubricate bolt for crankshaft sprocket. –  Install crankshaft sprocket; use counterhold tool -3415- to lock sprocket in place. Remaining installation steps are carried out in reverse sequence; note the following: –  Fit toothed belt (adjust valve timing): t  Vehicles to 04.2003 → Anchor. t  Vehicles from 05.2003 to 05.2004 → Anchor. t  Vehicles from 06.2004 → Anchor. –  Install poly V-belt → Chapter. –  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. Tightening torques

Component	Nm
Sealing flange to cylinder block	15
Toothed belt sprocket to crankshaft	90 + 90° 1)2)
Idler roller to bracket for ancillaries	25
l  1) Renew bolts. l  2) 90° = one quarter turn.