Audi Workshop Service and Repair Manuals

Removing and installing sealing flange (front) - vehicles up to 05.2003 Special tools and workshop equipment required

t  Counterhold tool -3415-

t  Assembly tool -T10053- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue

Removing –  Vehicles with auxiliary 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. Leave rear noise insulation in position. –  Remove bumper cover (front) → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50.

–  Remove poly V-belt → Chapter. –  Unbolt bracket -1- for refrigerant line. –  Disengage refrigerant line at bracket -2-.

–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor.   Caution The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-. –  Tie up air conditioner compressor with pipes attached to right-side of vehicle. –  Unbolt bracket for air-conditioner compressor → Item.

–  Unscrew bolts -arrows- and remove torque reaction support from sump. –  Remove toothed belt: t  Vehicles with hydraulically damped tensioning roller - engine codes AVB, AVF, AWX → Chapter. t  Vehicles with friction-damped tensioning roller - engine codes AVB, AVF, AWX → Chapter.

–  Remove crankshaft sprocket. To do this, counter-hold sprocket with special tool -3415-.

–  Remove 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. –  Carefully push the sealing flange onto the dowel pins on the engine block.

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

–  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. To do this, counterhold sprocket with counterhold tool -3415-. The remaining installation steps are carried out in the reverse sequence. –  Fit toothed belt (adjust valve timing): t  Vehicles with hydraulically damped tensioning roller - engine codes AVB, AVF, AWX → Anchor. t  Vehicles with friction-damped tensioning roller - engine codes AVB, AVF, AWX → Anchor. –  Install bracket for air conditioner compressor → Item –  Install air conditioner compressor → Rep. Gr.87. –  Install viscous fan → Chapter. –  Install vibration damper → Anchor. –  Install poly V-belt → Anchor. –  Install lock carrier with attachments → 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 bumper cover (front) → Rep. Gr.63.   Note After installing, allow sealant to dry for approx. 30 minutes Then (and only then) fill the engine with engine oil. Tightening torques

Component	Nm
Toothed belt sprocket to crankshaft	120 + 90° 1)
Sealing flange to cylinder block	15
Bracket for air conditioner compressor to cylinder block	25
Stop for torque reaction support	28
l  1) Renew bolt.