Front Engine Plate: Service and Repair

Sealing Flange, Belt Pulley Side

Special tools, testers and auxiliary items required

• Counter support (3415)

• Assembly tool (T10053)

• Torque wrench (5-50 Nm) (VAG 1331)

• Torque wrench (40-200 Nm) (VAG 1332)

• Hand drill with plastic brush attachment

• Flat scraper

• Silicone sealant (D 176 404 A2)

Removing

- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Remove the toothed belt, refer to one of the following:

• => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, without Divided Toothed Belt Guard.

• => [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, with Divided Toothed Belt Guard.

- Loosen the crankshaft toothed belt gear. Secure the toothed belt gear using the (3415).





- Remove the crankshaft toothed belt gear center bolt - 1 -, and gear - 2 -.





- Remove the diamond disc - 3 - from the toothed belt gear.

- Drain the engine oil.

- Remove the oil pan. Refer to => [ Oil Pan ] Oil Pan.

- Remove the sealing flange bolts.

- Remove the sealing flange, and if necessary loosen by applying light strikes using a rubber hammer.

- Drive out the seal with the sealing flange removed.

- Remove any sealant residue from the cylinder block with a flat scraper.

- Cover the seal with a clean cloth.

• If the oil seal is to be replaced, drive out the old oil seal.

- Remove any sealant residue from the sealing flange using a rotating plastic brush (wear safety glasses).





- Clean the sealing surfaces. They must be free of oil and grease.

Installing

- Cover the sealing surface of seal using a clean cloth before applying the sealant bead.

- Cut the tube nozzle at the front marking (nozzle diameter approximately 3 mm).





- Apply a sealant bead of approximately 2 to 3 mm as shown - arrows - onto the clean sealing surface of the sealing flange.

• Note the expiration date of the sealing compound.

• The sealant bead must not be thicker than 2 to 3 mm or excess sealant could get into the oil pan and clog the oil intake pipe strainer.

• Note the expiration date of the sealing compound.

• The sealing flange must be installed within 5 minutes after application of silicon sealant.

• To position the sealing flange with the seal installed, use the (T10053/1).

• After installing, allow the sealant to dry for approximately 30 minutes. Only after then may the engine oil be added.

- Position the sealing flange immediately and lightly tighten all the bolts - arrows -.





- Tighten the sealing flange bolts in a diagonal sequence.

• Tightening specification: 15 Nm.

- Remove any excess sealant. There must be no sealant located on the crankshaft bearing end and the sealing surface of the seal.

- Install the oil pan. Refer to => [ Oil Pan ] Oil Pan.

- Install a new seal for the crankshaft. Refer to => [ Crankshaft Seal, Belt Pulley Side ] Service and Repair.

- Install crankshaft toothed belt gear - 2 - with new diamond disc - 3 - and new center bolt - 1 -.





• There must be no oil on the contact surfaces between the toothed belt gear, diamond disc and crankshaft.

• Replace the center bolt and the diamond disc.

• The threads and shoulder must be free of oil and grease.

- Install the toothed belt gear - 2 - with diamond disc - 3 - and tighten the bolt - 1 - hand tight.





- Use the (3415) to tighten the crankshaft toothed belt gear bolt.





- Tighten the center bolt to 90 Nm and then an additional 90° (1/4 turn). The additional turn can be done in steps.

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

Install the toothed belt and adjust the valve timing, refer to one of the following:

• => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, without Divided Toothed Belt Guard.

• => [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, with Divided Toothed Belt Guard.