Front Engine Plate: Service and Repair

Sealing flange - belt pulley side, removing and installing





Special tools, testers and auxiliary items required
^ Counter support 3415
^ Assembly tool T10053
^ Torque wrench (5 to 50 Nm) V.A.G 1331
^ Torque wrench (40 to 200 Nm) V.A.G 1332

Not illustrated:

Special tools, testers and auxiliary items required
^ Hand drill with plastic brush attachment
^ Silicone sealant D 176 404 A2
^ Flat scraper
^ Protective glasses

Removing
- Remove ribbed belt.
- Remove toothed belt.





- Remove toothed belt crankshaft sprocket. To do this, lock toothed belt sprocket with counter support 3415.
- Drain engine oil.
- Remove oil pan.
- Unscrew front sealing flange.
- Remove sealing flange, loosening if necessary by applying light strikes with a rubber hammer.
- Remove sealant residue from cylinder block with a flat scraper.





- Remove sealant residue from sealing flange using a rotating plastic brush (wear safety glasses).
- Clean sealing surfaces. Sealing surfaces 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 silicone sealant.





- Cut off nozzle on tube of sealant at front mark (diameter of nozzle: approx. 3 mm).

Note:
^ The sealing compound bead must not be thicker than 2 - 3 mm, 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.

- Apply silicone sealant as illustrated to clean sealing surface of sealing flange.
- Set sealing flange in place immediately and lightly tighten bolts.

Note: To install the sealing flange with the seal already installed, use the guide sleeve T10053/1.

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





- Install toothed belt crankshaft sprocket and lock with counter support 3415.

Note:
^ There must be no oil on the contact surface between the toothed belt sprocket and crankshaft.
^ Always replace the central bolt.
^ The threads and shoulder must be free of oil and grease.

- Tighten new central bolt to 120 Nm and turn an additional 90° (1/4 turn, additional turn may occur in several stages).

The rest of the assembly is basically a reverse of the disassembling sequence.

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

Installing the toothed belt.
- Install ribbed belt.