Removal and Replacement

Front sealing flange, removing and installing





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

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





- Unbolt stop - 1 - - arrows -.





- Remove toothed belt crankshaft sprocket. Secure toothed belt gear using counter-hold tool 3415.
- Drain engine oil.
- Remove oil pan.
- Remove front sealing flange bolts.
- Remove sealing flange. If necessary, loosen by tapping lightly with a rubber mallet.
- Remove seal for crankshaft -ribbed belt side-.





- 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 so they are completely free of any oil or grease.

Installing

Note: The sealing flange must be installed and tightened within 5 minutes after application of silicon sealant.





- Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 3 mm).
- Apply silicone sealing compound, as shown, to clean sealing surface of the sealing flange.
^ Thickness of sealant bead - arrows - : 2 to 3 mm

Note: The sealing compound bead must not be thicker, otherwise excess sealing compound may enter the oil pan and block the oil suction pipe strainer.

- Set sealing flange in place immediately and lightly tighten bolts.
- Fasten sealing flange bolts in a diagonal sequence.
- Tightening torque: 15 Nm
- Remove excess sealant.
- Install oil pan.

Note: After installing, allow sealant to harden for approximately 30 minutes before replenishing engine oil.

- Install new seal.





- Install toothed belt gear-crankshaft using a new bolt and secure with counter-hold tool 3415.
- Tightening torque: 90 Nm + 1/4 turn (90°)

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

- Install limit stop for torque support.
- Tightening torque: 30 Nm
- Install toothed belt.