Audi Workshop Service and Repair Manuals

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

t  Counterhold tool -3415- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Parts catalogue

Removing –  Move lock carrier to service position → Chapter. –  Lift off engine cover -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. –  Remove poly V-belt.

–  Unscrew bolt -arrow- and remove idler roller for poly V-belt.

–  Remove toothed belt → Chapter. –  Remove crankshaft sprocket; use counterhold -3415- to lock sprocket in place.

–  Unscrew bolts -1 ... 10-. –  Pull off sealing flange (front). –  Drive out oil seal with 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 sleeves 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 -3415- to lock sprocket in place. Remaining installation steps are carried out in reverse sequence; note the following: –  Install toothed belt (adjust valve timing) → Anchor. –  Install the pulley → Chapter. –  Install poly V-belt → Chapter.

–  Install lock carrier with attachments → General body repairs, exterior; Rep. Gr.50. –  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten bolts -arrows-. –  Install front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Check headlight adjustment → Booklet803. Tightening torques

Component	Nm
Sealing flange to cylinder block	15
Toothed belt sprocket to crankshaft	90 + 90° → Note → Note
Idler wheel to bracket for ancillary units	25
Stop for torque reaction support to lock carrier	28

1)  Renew bolt. 2)  90° equals a 1/4 turn.