Front Engine Plate: Service and Repair

Sealing flange (belt pulley side), removing and installing





Special tools, testers and auxiliary items required
^ Counter-holder tool 3415
^ Assembly tool T10053
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Hand drill with plastic brush attachment
^ Silicone sealant D 176 404 A2
^ Protective glasses
^ Flat scraper

Removing
- Remove ribbed belt and tensioner.
- Remove toothed belt.





- Remove toothed belt crankshaft gear. To do this, lock toothed belt gear using counter support 3415.
- Drain engine oil.
- Remove oil pan.
- Remove front sealing flange.
- Remove sealing flange, and if necessary loosen by applying light strikes with a rubber hammer.





- Remove sealant residue from cylinder block with a flat scraper.
- Cover seal with a clean rag.
- Remove sealant residue from sealing flange using a rotating plastic brush (wear safety glasses).
- Clean sealing surfaces. They must be free of oil and grease.

Installing

Note:
^ Note the expiration date of the sealing compound.
^ The sealing flange must be installed within 5 minutes after application of silicon sealant.





- Cut off nozzle on tube of sealant at front mark (diameter of nozzle approx. 3 mm).
- Apply silicone sealing compound, as shown, to clean sealing surface of the sealing flange. Sealing compound bead must be:
^ 2 to 3 mm thick
^ and run on inside of bolt holes - arrows -.

Note:
^ The sealing compound bead must not be thicker, otherwise excess sealing compound could enter the oil pan and may block the oil suction pipe strainer. Likewise, it could drip onto the sealing surface of the crankshaft seal.
^ Before applying the bead of sealant, cover the sealing surface of the seal with a clean rag.

- Set sealing flange in place immediately and lightly tighten bolts.

Note: To position sealing flange with sealing ring installed, use guide sleeve T10053/1.

- Fasten sealing flange bolts in a diagonal sequence. Torque specification: 15 Nm
- Remove excess sealant.
- Install oil pan.

Note: After installing, allow sealant to dry for approx. 30 minutes. Only after then may the engine oil be replenished.





- Install toothed belt crankshaft sprocket and lock with counter support 3415.
- Tighten new center bolt to 90 Nm plus an additional 90°(1/4 turn, additional turn may occur in several stages).

Note: The threads and shoulder must be free of oil and grease.

- Install toothed belt and adjust valve timing.
- Install ribbed belt and tensioner.